Titanium Magnetite Ore Research Articles

The use of block modeling to predict the variability of the bulk weight of titanomagnetite ore

The article presents the results of the performed studies using block modeling technologies to determine the volume weight of the titanium magnetite ore of the Northern deposit of the Gusevogorsky deposit, developed by EVRAZ KGOK OJSC. The methods used for laboratory studies of samples of titanium magnetite ore from exploration wells are described. The results of statistical processing of the obtained data are presented. The relationship between the bulk weight of the ore and the iron content in it has been established. Based on block modeling of the massif, a forecast was made for the deep horizons of the Northern Quarry of JSC EVRAZ KGOK on changes in the volume weight of ore and the total iron content in it, which will allow the company's specialists to use the obtained data in geological and technological calculations.

HIsarna Process Simulation Model: Using FactSage with Macro Facility

The HIsarna process is one of the emerging technologies for reducing the carbon footprint of the ironmaking process, which is currently in the pilot plant stage. A kinetic HIsarna process simulation model based on the effective equilibrium reaction zone concept has been developed using the FactSage macro programming facility to advance understanding of the whole process. In the model, the HIsarna process is conceptually divided into various equilibrium zones involving combustion, coal pyrolysis and gasification, gas/slag/carbon reactions, and slag/metal reaction. The model has been validated through the pilot plant data, and the results are in good agreement with the quantity and composition of hot metal, slag, and gas. The HIsarna off-gas stream with high CO2 content can potentially allow capture and storage directly for carbon mitigation. The utilization of titanium magnetite ore in the HIsarna process has also been investigated via the developed model. The injection of titanium magnetite ore which has high FeO content decreases coal consumption. Still, it increases the slag volume as higher gangue content when keeping the same productivity as the pilot plant trial. The HIsarna process shows promising potential in using low-quality high titania iron ore as feed materials, but the slag system needs to be further optimized. From the heat distribution, the off-gas sensible heat accounts for a large part of the input heat due to its high temperature but can be recovered with good efficiency. The present model is an efficient tool for understanding the HIsarna process and providing theoretical guidance for future pilot research.

HYDROFLUORIDE PROCESSING OF TAILINGS FROM WET MAGNETIC SEPARATION OF TITANOMAGNETITE TO OBTAIN AMORPHOUS SILICON DIOXIDE

A method for the opening of silicon-containing technogenic feedstock using an aqueous solution of ammonium bifluoride (NH4HF2) with subsequent production of amorphous silica has been developed. In this work we examined wet magnetic separation tailings (WMST) – iron titanium-magnetite ore enrichment rejects that are formed in huge quantities and stored in sludge depositories at concentrating plants. The main rock-forming minerals of WMST are resistant silicates – pyroxene, amphibole, plagioclase and olivine with the total SiO2 content of about 50%. It was established that fluorination of silicon-containing minerals begins during mechanical dispersion of a dry reaction mixture at room temperature. The thermodynamic calculations confirm active interaction of components in the composition of mineral complexes already at 25 ℃, some of the processes being exothermic with entropy reserve. When the temperature increases to 90 ℃ and the duration of leaching to 5 h, the extraction of silicon in the form of soluble ammonium fluorosilicate grows. Insoluble calcium and magnesium fluorides and sparingly soluble under leaching conditions ammonium fluorometallates, as well as a part of unreacted rock are formed in the insoluble residue. Under the most effective desilication conditions (20% NH4HF2 solution, L:S=4:1, 2 h), the residual content of SiO2 decreases to 1–2%. The synthesis of finely dispersed amorphous silica (SiO2) was performed by hydrolytic deposition when the value of рН of clarified ammonium fluorosilicate solution was reduced by adding ammonia. It was shown that gradual introduction of hydrous ammonia (5 ml/h) into diluted fluorosilicate solution with a concentration of less than 5 g/l Si while constant stirring leads to the formation of spherical silica nanoparticles. The degree of silica extraction from tailings in the process of hydrofluorination of 20% NH4HF2 solution at 90 ℃ for 2 h was 98%, and the content of impurities in amorphous silica did not exceed 1–2%. Separation of finely dispersed suspension of insoluble fluorides and hydroxide impurities formed during stepwise hydrolysis of fluorosilicate solution to рН value less than 5 is a necessary condition for producing pure silica SiO2. The final product, similar to “white soot” in properties, is characterized by predominant particle size in the interval of 2-20 nm, a large surface area 230-360 m2/g and a low pycnometric density 1.62 g/cm3. For citation: Medyankina I.S., Pasechnik L.A. Hydrofluoride processing of tailings from wet magnetic separation of titanomagnetite to obtain amorphous silicon dioxide. ChemChemTech [Izv. Vyssh. Uchebn. Zaved. Khim. Khim. Tekhnol.]. 2023. V. 66. N 2. P. 70-77. DOI: 10.6060/ivkkt.20236602.6706.

Development of Vanadium Recovery Process Using Reduction Pre-treatment from Vanadium Titanium-Magnetite (VTM) Ore

Development of Vanadium Recovery Process Using Reduction Pre-treatment from Vanadium Titanium-Magnetite (VTM) Ore

Study on the mineral characteristics and separation performances of a low-TiO2 ilmenite

• Ilmenite-M had a lower TiO 2 grade and a higher Fe content than common ilmenite. • Ilmenite-M existed variations in element contents of (Fe, Mg)(Ti, Fe)O 3 . • Ilmenite-M was ferromagnetic while common ilmenite was paramagnetic. • Ilmenite-M emerged a better floatability compared to common ilmenite. • Ilmenite-M would be captured priority over common ilmenite. A low-TiO 2 ilmenite (ilmenite-M) was separated from the vanadium–titanium magnetite ore in Panzhihua, and its chemical composition and separation behaviors were investigated compared to common ilmenite. The chemical composition and structure analysis indicated that ilmenite-M had 43.53% TiO 2 but a high Fe content and two types of ilmenite together with a spot of maghemite appeared in the ilmenite-M grains. The vibrating sample magnetometer (VSM) analysis presented that ilmenite-M was strong ferromagnetic and its specific susceptibility was greater than that of paramagnetic ilmenite. Ilmenite-M performed a better floatability than common ilmenite. It was suggested that sodium oleate (NaOL) adsorbed onto ilmenite-M surfaces more than common ilmenite and Ca was served as a new active site response to the NaOL adsorption on ilmenite-M surfaces. Therefore, ilmenite-M would be captured before common ilmenite in the beneficiation of ilmenite ore through high-intensity magnetic separation and froth flotation, decreasing the TiO 2 grade of the final concentrate.

Impact of Initial Titanium Magnetite Ore Material Composition on Fluxed Pellet Metallurgical Properties

Research work was carried out on the test units with the conditions close to the industrial ones to study the material composition impact of the concentrates produced from various types of the Kachkanar titanium magnetite ores on the fluxed pellet metallurgical properties. In order to study the pellet properties with a small number of experiments the simplex-lattice design method was used. Data was quoted on variation of key quality parameters of pellets from particular concentrate types and their mixture at certain horizons throughout the bed height with regard to a conveyer-type roast machine. An expression was obtained for the weighted average strength of commercial pellets. According to the data obtained in the course of the experiments with certain concentrate types and their well-balanced mixtures the expressions were introduced as incomplete cubic polynomials describing the key quality parameter variations of the pellets from optional composition mixtures. The work results are of certain interest for the process engineers and specialists dealing with iron ore raw material preparation, as they allow forecasting of high quality fluxed pellet production from various material composition concentrates.

Integrated study on obtaining oxide pellets from brown iron ore

Introduction. Currently, the main raw materials for the production of cast iron and steel at metallurgical plants are iron concentrates obtained from magnetite (ferrous) quartzites, titanium-magnetite, and skarn ores. The existing technologies for processing these types of ores, which mainly include separation processes based on magnetic properties, size, separating of equally falling grains, and surface wettability allow us to produce both ordinary iron concentrates and high quality ones. The use of such schemes in the processing of brown iron ore does not allow obtaining high rates of mineral concentration. One of the methods for processing this type of ore is a roasting-magnetic scheme, which allows converting weakly magnetic (non-magnetic) forms of iron into strongly magnetic ones. Research objective is to develop the mode of magnetizing roasting of brown iron ore, technology of concentrating of the burn-out product in order to obtain iron concentrate and oxide pellets. Methods of research. The duration of heat treatment of the charge consisting of iron ore from the Abail deposit and coal from the Ekibastuz deposit and the required mass fraction of solid carbon contained in the coal are determined. Technological studies of the roasted product were carried out in order to obtain a concentrate with a mass fraction of iron at least 67%. According to the developed technology, a batch of iron concentrate was developed in order to obtain and study raw and oxide pellets. Results. The modes of magnetizing roasting of brown iron ore from the Abail deposit and cooling of the roasted material have been developed. A scheme for mineral processing of the roasted material has been developed in order to obtain a concentrate with at least 67% of iron mass fraction. The process of obtaining strong raw and roasted pellets from iron concentrate is studied. Conclusions. The developed mode of magnetizing roasting of the charge consisting of coal and ore from the Abail deposit makes it possible to obtain a roasted product with a degree of magnetization of 93%. The using of desliming of the roasted product makes it possible to remove magnetic floccules from the processing that reduce the concentrate quality, and to obtain a concentrate with a mass fraction of iron of at least 67% in the last stage of magnetic separation. From the iron concentrate, it is possible to obtain oxidized pellets with a strength of at least 200 kg/pellet at temperature of pellets firing of 1325 °C.

A mathematical model of metallization of titanium-magnetite ores of Kachkanar deposit in Midrex shaft furnace

Development of a technology for obtaining direct reduction iron from titanium-magnetite ores, which will be the main ore base of the Ural ferrous metallurgy in the future, is one of the urgent tasks of metallurgical science. The world and domestic experience of the development of direct iron reduction processes, which are the most environmentally friendly of all existing methods of obtaining iron from ore considered. It was shown that the technology of metallization of iron ore materials in the Midrex shaft furnace has received the most widespread application. It is noted that the accumulated experience of using Midrex technology in Russian Federation will allow increasing the production of metallurgical raw materials with a reduced carbon footprint. An algorithm and a block diagram for calculating technical and economic indicators of the metallization process for the Midrex process shaft furnace are described. A methodology for calculating material and thermal balance of the Midrex process has been developed, taking into account the use of iron ore raw materials containing vanadium and titanium in the charge. On its basis, an algorithm was developed and a mathematical model of the metallization process was implemented, calculations of the metallization process of titanium-magnetite pellets obtained from the ores of the Kachkanar deposit in the Midrex mine furnace were performed. A comparison of the indicators of the metallization process of titanomagnetite pellets carried out in the shaft furnace of JSC “OEMK named after A.A. Ugarov” and obtained using the created software product showed satisfactory convergence of the results.

Features of the Geological Structure and Genesis of the Tebinbulak Deposit (Ridge Sultan-Uvais)

In this article, we want to draw attention to the hysteron-magmatic origin of titanium-magnetite ores of the Tibinbulak gabbro-peridotite complex located in the northwestern part of the Sultan-Uvais ridge. Which is the only outlet of the Phanerozoic foundation between the mountain structures of the Urals and the Southern Tien Shan. The article examines the characteristic features of petrochemical and structural features of ore minerals (ilmenite, magnetite) and the main rock-forming minerals of the gabbro-peridotite complex (peridotite, pyroxenite, tebinnite, pyroxene hornblendite and plagioclase) with clarification of the structural relationships. It was found that magnetite mineralization of the Tebinbulak intrusion was superimposed on ultrabasic rocks in the final stages of crystallization of the latter. Prolonged auto-metasomatic transformations led to the enlargement of magnetite crystals in places subject to decay. In this case, aggregates of spinel - hercynite with sphene rims were formed. Simultaneously with the formation of sphene, ilmenite crystals appeared in the form of radiant needle-shaped aggregates. In this case, the primary crystals of magnetite lost their faces and became shapeless. Relatively large precipitates of titano-magnetite formed at this stage with the filling of cracks in the rock and interstices between minerals. Based on the data presented, we note that the titano-magnetite ores of the Tebinbulak deposit arose in the late magmatic (hysteron-geneous) setting of auto-metamorphic replacement of the main carriers of iron and titanium pyroxene and plagioclase with hornblende. Also, the studied geochemical composition of ores damages that the titano-magnetite ores of the Tebinbulak deposit are a complex raw material, from which not only iron but also vanadium concentrate can be extracted.

Increasing the strength of pellets made of titanium-magnetite concentrates when using additives containing barium and strontium

In the process of pelletizing of titanium-magnetite ores concentrate, the high viscosity of the forming titaniferous melts makes the pellets sintering difficult resulting in their low strength. The reserves of the existing methods of solving the problem by addition of oxides of waste rock and therefore decreasing titanium concentration or by assortment of optimal heat mode of the technological process are exhausted. An ability to decrease the viscosity of titaniferous melt by application monoxides of iron, manganese, boron and alkali oxides of potassium, sodium and strontium for its dilution was considered. It was shown that the alkali additives were a powerful method to decrease the viscosity of silicate melts. The purpose of the study was to estimate an ability to in-crease the strength of iron ore pellets of titanium-magnetite concentrates by addition barium-strontium carbonate ores of Murunskoye deposit into the charge, which have and increased content of oxides of barium and strontium (up to 19% BaO and up to 5% of SrO). As a result of the experiment a mechanism of pellets strengthening at addition carbonate barium-strontium ores was established. The increase of the burnt pellets strength was reached up to 35–40%. It was shown, that the pellets strengthening was stipulated by modi- fication of slag melt structure with destruction of polymer chains and by decrease of melt viscosity. The increase of pellets strength will contribute to decreasing of fines yield during their transportation and to improving of gas-dynamic mode of shaft facilities – blast furnaces and metallization furnaces. The forecast effect due to application of additives in the pellets is estimated as follows: decrease of coke rate by 4.5–5.8 kg/t of hot metal and decrease of cast iron cost by 49.5–64.3 Rbl/t of cast iron.

Smelting of titanium-magnetite metallized pellets from the Tebinbulak deposit ore in submerged arc furnaces

Utilization of titanium-magnetite ores as complex raw materials aimed at extraction of iron and vanadium is an important and actual task. Technological capability of titanium-magnetite pellets application produced from the Tebinbulak deposit ore was studied for obtaining sponge iron and its further use in the production of liquid iron. Integrated theoretical and experimental studies of Tebinbulak deposit ore were carried out within the framework of the state program of the Republic of Uzbekistan by the company JSC “Uzbek Railways” (Republic of Uzbekistan, Tashkent) in cooperation with Horst Wiesinger Consulting (Austria, Linz) on the basis of the Research Center of the Leoben Mining University (MUL, Austria, Leoben), Studiengesellschaft für Eisenerzaufbereitung (SGA, Germany, Liebenburg-Othfresen) with the participation of the North Caucasus Mining and Metallurgical Institute (State Technological University) (Russia, Vladikavkaz). Experiments on direct solid-phase reduction of fired oxidized pellets have been implemented in a vertical retort in a hydrogen atmosphere at a temperature of 800 °C. As a result of the tests, the planned degree of metallization of the pellets was achieved, which averaged 93%. The obtained metallized pellets were melted in a 45 l volume furnace with a submerged electric arc. As a result of the tests, the target value of the carbon content in the liquid iron was achieved, which amounted for 4.3 – 4.6%. It was noted that according to the results of two heats, TiO 2 almost completely passed into the slag phase, where its average value was 3.55%.Average vanadium content of the liquid iron was 0.16%. During the studies it was found that at a chemically measured value from 0.71 to 0.73% V 2 O 5 in metallized pellets, the calculated theoretical maximum content of vanadium in liquid iron 0.49% can be achieved, providing all vanadium remains in the metal phase.

Physical-Chemical and Pyrometallurgical Estimation of Processing of Complex Ores with Extraction of Iron, Vanadium, Titanium

The metallurgical characteristics of pellets (reducibility, strength after reaction, softening start and end temperatures), phase composition (X-ray phase analysis), and porosity were studied. Blast furnace smelting parameters were calculated using laboratory pellets with different basicities and degrees of metallization. Pellets were obtained from complex titanium-magnetite ores. The vanadium extraction of this ore into metal did not exceed 10 % during smelting of metallized pellets in an arc steelmaking furnace, but special techniques could raise this to 85 %. According to calculations from the Institute of Metallurgy of the Ural Branch of the Russian Academy of Sciences (IMET UB RAS), vanadium extraction up to 80–90 % can be achieved by using high-base and partially metallized pellets. The influence of changes in the composition and metallurgical characteristics of titanomagnetite pellets with increasing basicity (especially relative to strength after reduction) should be taken into account.

Preparation, Sintering Behavior and Consolidation Mechanism of Vanadium-Titanium Magnetite Pellets

High-quality oxidized pellets are the basis to achieve high-efficiency utilization of vanadium–titanium magnetite (VTM) ores. Bentonite was used as a binder of VTM. The main phase composition of VTM is titanomagnetite and ilmenite. When the amount of bentonite is 1%, the compressive strength and dropping strength of VTM pellets can meet the requirements. To improve metallurgical properties, the pellets need to be roasted. The best conditions for roasting are as follows: calcination temperature of 1523 K and a calcination time of 20 min. The consolidation mechanism, phase transformation, and crystal structure transformation of VTM in the process of oxidation roasting are also explained.

Magnetic Separation Behavior of V, Ti, and Fe of Fractured Products from Domestic Vanadium Titanium-Magnetite (VTM) Ore

Magnetic Separation Behavior of V, Ti, and Fe of Fractured Products from Domestic Vanadium Titanium-Magnetite (VTM) Ore

Feasibility of Applying a Rotary Kiln to Roast Vanadium in Domestic Titanium-Magnetite Ore

Feasibility of Applying a Rotary Kiln to Roast Vanadium in Domestic Titanium-Magnetite Ore

Mineral-derived catalysts optimized for selective catalytic reduction of NOx with NH3

A type of novel mineral-derived catalyst (MDC) composed of vanadium–titanium magnetite and sintering ore was prepared via calcination or acid modification for selective catalytic reduction of nitrogen oxides (NOx) with ammonia (NH3) to reduce the production cost and simplify the preparation process. Characterizations by X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectrometry (EDS) mapping, X-ray photoelectron spectroscopy (XPS) and temperature-programmed reduction of hydrogen (H2–TPR) characterizations were performed to observe the evolution of the physicochemical properties of the mineral catalyst during modification, which were corelated to their catalytic activity. The in-situ DRIFTS was also investigated to discuss the reaction mechanism for different catalysts. The results show that the mineral catalysts with sulfuric acid modification exhibit high NOx conversion (above 90% at 350 °C) and sulfur resistance due to the formation of ferric sulfate species and the presence of Fe3+/Fe2+ and V5+/V4+ couples in the catalysts that results in abundant Brønsted acid sites and promotes the redox properties of catalysts. The in-situ DRIFTS results indicate that the catalysts modified by calcination-pretreatment primarily follow the Langmuir-Hinshelwood (L–H) mechanism where gaseous NO is more easily adsorbed on α-Fe2O3 to form stable nitrates and react with a small number of NH3 species adsorbed on α-Fe2O3, leading to decreased activity. On the other hand, the catalysts modified with acid mainly follow the Eley-Rideal (E–R) mechanism in which adsorbed nitrogen species show less thermal stability and a large amount of adsorbed NH3 on the ferric sulfate species directly react with gaseous NO, resulting in the higher activity.

Pyrometallurgical processing of high-titaniferous ores.

The future development of Ural mineral and raw materials base of steel industry is considerably stipulated by the development of deposits of titanium-magnetite ores, the reserves of which are accounted for near 77% of iron ores of Urals. It was shown, that the content of titanium dioxide as well as harmful impurities in the titanium-magnetite have the decisive meaning for selection of processing technology of them for extraction out of them vanadium and other useful components. Technological schemes of the titanium-magnetite enrichment and industrial methods of titanium-magnetite concentrates processing considered. Examples of titanium-magnetite processing by coke-BF and coke-less schemes given. The problems of blast furnace melting of titanium-magnetite ores highlighted. Main problems relate to formation of refractory compounds in a form of carbo-nitrides during reduction of titanium and infusible masses in blast furnace hearth. It was shown, that intensification if carbides precipitation is stipulated by increase of intensity of titanium reduction at increased temperatures of a heat products and requires the BF heat to be run at minimal acceptable temperature mode. Technological solutions, necessary to implement in blast furnace for iron ore raw materials with increased content of titanium processing were presented, including increase of basicity of slag from 1.2 to 1.25-1.30, increase of pressure at the blast furnace top from 1.8 to 2.2 atm, decrease of silicon content in hot metal from 0.1 to 0.05%, application of manganese-containing additives. It was noted, that theoretically the blast furnace melting of titanium-magnetite is possible at titanium dioxide content in slag up to 40% when application of the abovementioned technological solutions, silicon content in hot metal to 0.01% and very stable heat conditions of a blast furnace. The actuality of titanium and its pigmental dioxide production increase was noted. Possibilities of development of Medvedevskoje and Kopanskoje deposits of high-titaniferous ores in Chelyabinsk region with extraction not only iron and vanadium but also titanium considered.

Effect of Preformed Calcium Ferrite Addition on Sintering Behavior of Vanadium Titanium Magnetite Ore

A new approach is proposed to improve the strength of the vanadium titanium magnetite (VTM) sinter by adding preformed calcium ferrite (CF) to partially substitute the CaO. The effects of the sintering temperature, oxygen partial pressure (pO2), heating time, and substitution ratio of preformed CF on the mineralogy of the VTM sinter are examined through tablet sintering. The results indicate that sintering temperature significantly affects the matrix structure and pore morphology by influencing solid–liquid assimilation and bubble coalescence. With an increase in pO2, the generation of calcium ferrites and hematite is favored, and the matrix transforms into a melting corrosion structure. Heating time mainly affects the pore shape. The addition of preformed CF to VTM sintering can not only inhibit the generation of perovskite and promote the formation of calcium ferrites but also increase the quantity of melts and promote solid–liquid assimilation.

Comparative analysis of the results of vanadium chemical extraction out of Ural titanium-magnetite ore tails and concentrate

Demand for vanadium significantly exceeds supply at the world market, determining the relevance of research on the involvement of various raw materials and technological processes to increase its production. The research was carried out to increase the efficiency of the vanadium extraction process out of titanium-magnetite ore concentrate and titanium-magnetite ore enrichment tails. For the study, samples of Ural titanium-magnetite ore tails and concentrate with different chemical compositions were used. The effect of roasting temperature, the amount and type of reagents for roasting and leaching on the vanadium extraction degree was studied. Na 2 CO 3 or NaCl were used as reaction additives to the charge for roasting of tails, and Na 2 CO 3 was used for roasting of concentrate samples. The content of the reagent Na 2 CO 3 or NaCl varied and amounted to 23, 33, 40 and 50% of the charge mass. Oxidative roasting was carried out at temperatures of 700, 850 and 950°C. It was shown that an increase of the Na 2 CO 3 content in the charge with the concentrate from 23 to 40%, results in increasing of the degree of vanadium extraction from 36 to 54%. An increase in the NaCl content from 23 to 40% in the charge with tails results in increasing of the vanadium extraction degree from 32 to 46%, and at NaCl content 50%, the vanadium extraction degree increased to 64%. An increase in the roasting temperature of the charge from 700 to 950°C led to an increase in the vanadium extraction degree to 71-83.1% in different ore samples. Chemical extraction of vanadium out of unroasted concentrate samples was carried out by leaching with hydrochloric acid HCl. An increase in the concentration of HCl from 10 to 30% led to an increase in the vanadium extraction degree from 15 to 44%.

Review of State and Prospects for Development of Vanadium Production in the Kazakhstan Republic

Information is provided about prospects for vanadium ore deposits in Kazakhstan, the history of exploration of the deposits of Greater Karatau (Southern Kazakhstan), and mineralogical study indicating the potential for the involvement of vanadium raw materials in production. A review of the state and prospects for the development of vanadium production in the Republic of Kazakhstan demonstrates the possibility of creating enterprises for ammonium metavanadate production, organization of ferroalloy production, and a vanadium battery enterprise. The Karatau vanadium bearing basin appears to be very promising; first, the vanadium content is greater by a factor of 8–10 than the titanium magnetite ores of Russia and South Africa (traditionally industrially processed ores). Second, the ore contains such useful components as carbonaceous matter (8–10%), silica (SiO2 up to 80%), and REM (0.02%). Third, a newly constructed plant (2018–2021) in the Kyzylorda region will require a significant amount of siliceous and carbonaceous raw materials for the production of ferrosilicon and vanadium for vanadium batteries. Fourth, an important factor is the proximity of the Balasauskandyk and Kurumsak fields to the regional center of Kyzylorda (160–180 km), where it is planned to build ferroalloy plants and a vanadium battery plant.