Improving the production efficiency of high-titania slag in Ti extraction process: fluxing effect on formation of pseudobrookite

We investigated the carbothermic reduction process of ilmenite ore at 1873 K with flux addition. Without flux, the pseudobrookite phase with a high melting temperature was precipitated during ilmenite smelting. This could be the main reason for decreased reduction of iron in ilmenite. To accelerate reduction of ilmenite, two factors were considered. One is increasing the reduction driving force during smelting. Activity of FeO is the major factor to control reduction in driving force. The other factor is delay in formation of the pseudobrookite phase, a high-melting point precipitation phase. In this system, MgO in ilmenite could be used to form pseudobrookite. To control these factors, in this study, flux agent (i.e., Na(2)O or SiO(2)) addition was considered. The thermochemical simulation program, FactSage(TM)7.0 was used to calculate the viscosity of slag and the activity of components as fluxing agents were added. High-temperature experiments using an induction furnace were also conducted to confirm the computational results. To determine the composition of final products, i.e., titanium slag, X-ray fluorescence analysis was executed. As a result of Fe and Ti behaviours in slag, SiO(2) addition showed no significant difference from the slag without flux. However, Fe reduction in ilmenite, i.e. TiO(2)-enrichment, was more accelerated when Na(2)O was added. X-ray diffraction, scanning electron microscopic and transmission electron microscopic analyses results also showed that even 1 wt% Na(2)O addition significantly influenced the titanium slag production compared to no flux addition.