Extraction of Titanium Dioxide from Ilmenite

Summary

This graduation project focuses on extracting titanium dioxide from ilmenite ore, conducted by the fourth batch of the Chemical Engineering Department at the Egyptian Academy of Engineering and Advanced Technology. The project explores the extraction process based on Egypt's Vision 2030, aiming to enhance the added value of raw materials. The study involves various chemical methods, including using sulfuric acid and conducting several experiments to optimize extraction conditions. The project also incorporates economic analysis, energy balance, and equipment design for scalability. The final product, titanium dioxide, is both economically viable and environmentally friendly, offering significant profit potential in the global market.

Takeaways

• 😀 The project is a graduation project from the 4th batch of the Chemical Engineering Department at the Egyptian Academy of Engineering and Advanced Technology.
• 😀 The project focuses on the extraction of titanium dioxide from ilmenite, which is a mineral abundant on Egypt's coasts.
• 😀 The goal of the project is aligned with Egypt's Vision 2030, aiming to add value to raw materials, reduce imports, and increase national income through local manufacturing.
• 😀 Titanium dioxide (TiO2) has multiple uses, including in paints, solar panels, and medical applications, making it a highly valuable material.
• 😀 The extraction process was based on the study of various methods, using materials provided by the Egyptian Black Sand Company and considering economic factors.
• 😀 The optimal extraction conditions were determined, including a reaction time of 4 hours and a temperature of 120°C using a 12 M sulfuric acid solution, achieving up to 84% extraction efficiency.
• 😀 The extraction process involves four main steps: leaching, filtration, hydration, and calcination.
• 😀 In the leaching step, ilmenite is mixed with sulfuric acid at a ratio of 1:5 and heated to 120°C. After 4 hours, the reaction is stopped to form titanium sulfate.
• 😀 After leaching, the titanium sulfate is separated from the solid residues, filtered, and then subjected to a hydration process to form titanium dioxide hydride.
• 😀 The project also optimized the process by utilizing the by-products (such as ferrous sulfate) for water treatment applications, improving the overall process sustainability and economic benefits.
• 😀 A comprehensive economic study was conducted, determining that the project would cost $1200 per ton of titanium dioxide, which can be sold for $2300 per ton, yielding a return on investment of 84%.

Q & A

What is the primary focus of the graduation project described in the script?

The primary focus of the project is the extraction of titanium dioxide (TiO₂) from minerals, specifically using alumina as the raw material, and exploring the various methods of extraction to improve the efficiency of the process.

Why is titanium dioxide (TiO₂) considered important in this project?

Titanium dioxide has several important uses, including in paints as a pigment, in solar panels, and for medical applications. Its widespread applications make it valuable in various industries.

What is the significance of the raw material alumina in this project?

Alumina is a readily available raw material on Egypt's coasts and is used in the extraction of titanium dioxide. The project's aim is to utilize this local resource to create value-added products, reducing reliance on imports.

Which extraction method was chosen for the project, and why?

The sulfuric acid leaching method was chosen for the extraction of titanium dioxide from alumina. This method was selected based on preliminary analyses and the economic feasibility of the process.

What kind of laboratory analyses were conducted on the raw material before extraction?

Initial analyses on the raw material included X-ray diffraction (XRD), X-ray fluorescence (XRF), and screening analysis to understand the properties of the material and inform the extraction process.

What were the optimal conditions determined for the extraction of titanium dioxide?

The optimal conditions for the extraction were found to be a reaction time of 4 hours and 30 minutes at a temperature of 120°C, with sulfuric acid at a concentration of 12 molar. Under these conditions, the extraction efficiency reached 84%.

How was the extraction process structured in terms of its steps?

The extraction process consists of four main steps: leaching, filtration, hydration, and calcination. These steps are designed to separate titanium dioxide from other impurities in the raw material.

What was the role of the hydraulic step in the extraction process?

The hydraulic step involved mixing the filtered solution with water to form a reaction under controlled conditions, which resulted in the formation of titanium hydride, a precursor to titanium dioxide.

How was the titanium hydride transformed into titanium dioxide in the process?

After the hydraulic step, the titanium hydride gel was separated and dried. The dried gel was then subjected to calcination at temperatures between 500-800°C to produce titanium dioxide, either in rutile or anatase form, depending on the desired end product.

What economic considerations were made for scaling up the titanium dioxide production?

An economic study was conducted to estimate the investment and operating costs, as well as potential revenue. The final cost of producing titanium dioxide was found to be $1200 per ton, with a selling price of $2300 per ton, offering a competitive price in the global market. The project was expected to yield an 84% return on investment.