AU678375B2 - Upgrading titaniferous materials - Google Patents

Description

OPI DATE 15/03/94 AOJP DATE 09/06/94 APL.ID 46915/93 11111111111 II~~ll111fl iiIl PCT NUMBER PCT/AU93/004141111111111I IIlllI11 111iiii AUJ9346915

INT.

(51) International Patent Classification (11) International Publication Number: WO 94/04709 C22B 1/00, 1/02 C22B 34/12 Al (43) International Publication Date: 3 March 1994 (03.03.94) (21) International Application Number,.

(22) Internaional Filing Date: 1 Priori data.- PL4105 14 Augusi PL 7193 10 Fcbrua PCT/AU93/004 14 2 August 1993 (12.08.93) 1992 (14.08.92) AU iry 1993 (10.02.93) AU (74) Agent: BLAI R, Griffith Hlack Co., 3rd Floor, 509 St. Kilda Road, Melbourne, VIC 3004 (AU).

(81) Designated States: AT, AU, DOI, 11G. DR, BY, CA, CH, CZ, DE, DK, ES, Fl, GBl, HlU, JP, KP, KR, KZ, LK.

LU, MG, MN, MWV, NL, NO, NZ, PL, PT, RO, RU, SD, SE, SK, UA, US, VN, European patent (AT, BE, CH, DE, DK, ES, FR, GB, GR, IIE, IT, LU, MC, NL, PT, SE), QAPI patent (BF, BJ, CF, CG, CI, CM, GA, GN, ML, MR, NE, SN, TD, TG).

Published 111th international search repor.

(71) Applicant (for all designated States wxept US): TECHNO.

LOGICAL RESOURCES PTY LIMITED [AU/AU]; A.C.N. 002 1833 557, Level 39, 55 Collins Street, Melbourne, VIC 3001 (AU), (72) Inventors; and Inventors/Applicants (for US onlyj) HOLLITT, Michael, John [AU/AU]; 80 Tyne Street, Box Hill North, VIC 3129 McCLELLAND, Ross, Alexander [AU/ AU]; Lot 136 Murrawong Road, Maryknoll, VIC 3812 TUFFLEY, John, Roger [AU/AU]; 15 Hill Street, Burnside, S.A. 5066 (AU).

678 375 (54) Thie: UPGRADING TITANIFEROUS MATERIALS (57) Abstract Tfhe application discloses a process ror upgrading a titaniferous material by removal or impurities contained in the material especially radionuclides. The process involves heating the titaniferous material to a temperature or less than 1300 'C to fornm a solid titaniferous phase and a liquid oxide or glassy phase in the presence of a material that promotes the formations of such phases, cooling the product at a rate that maintains the glassy phase in an amorphous state and leaching the solidified material with an acid or an alkali to remove the impurities. Materials that promote the formation of the desired phases include compounds of alkali metals and boron, Examples include borax, caustic soda, soda ash and silica.

WO 94/04709 PCT/AU93/00414 1 UPGRADING TITANIFEROUS MATERIALS This invention relates to the removal of impurities from naturally occurring and synthetic titaniferous materials.

The invention is particularly suited to the enhancement of titaniferous materials used in the production of titanium metal and titanium dioxide pigments by means of industrial chlorination systems.

Embodiments of the present invention have the common feature of roasting of titaniferous materials in the presence of additives and at temperatures which encourage the formation of a liquid oxideA ph followed at some stage by cooling and aqueous leaching as steps in an integrated process. Additional steps may be employed as will be described below.

In industrial chlorination processes titanium dioxide bearing feedstocks are fed with coke to chlorinators of various designs (fluidised bed, shaft, molten salt), operated to a maximum temperature in the range 700 1200C. The most common type of industrial chlorinator is of the fluidised bed design. Gaseous chlorine is passed through the titania and carbon bearing charge, converting titanium dioxide to titanium tetrachloride gas, which is then removed in the exit gas stream and condensed to liquid titanium tetrachloride for further purification and processing.

WO 94/04709 PCT/AU93/00414 2 The chlorination process as conducted in industrial chlorinators is well suited to the conversion of pure titanium dioxide feedstocks to titanium tetrachloride.

However, most other inputs impurities in feedstocks) cause difficulties which greatly complicate either the chlorination process itself or the subsequent stages of condensation and purification and disposal of waste. The attached table provides an indication of the types of problems encountered. In addition, each unit of inputs which does not enter products contributes substantially to the generation of wastes for treatment and disposal. Some inputs particular metals, radioactives) result in waste classifications which may require specialist disposal in monitored repositories.

Preferred inputs to chlorination are therefore high grade materials, with the mineral rutile (at 95-96% TiO,) the iost suitable of present feeds. Shortages of rutile have led to the development of other feedstocks formed by upgrading naturally occurring ilmenite (at 40-60% TiO,), such as titaniferous slag (approximately 86% TiO 2 and synthetic rutile (variously 92-95% TiO,). These upgrading processes have had iron removal as a primary focus, but have extended to removal of magnesium, manganese and alkali earth impurities, as well as some aluminium.

111111 1 I WO 94/04709 PCT/AU93/00414 Elemental Input Chlorination Condensation Purificatia Fe, Mn Alkali alkali earth metals Consumes chlorine, coke, increases gas volumes Defluidise fluid beds due to liquid chlorides, consume chlorine, coke Consumes chlorine, coke Accumulates in chlorinator, reducing campaign life.

Consumes coke, chlorine Solid/liquid chlorider foul ductwork, make sludges Al Causes corrosion Can encourage duct blockage.

Condenses in part with titanium tetrachloride Causes corrosion, makes sludges May require distillation from product Must be removed, by chemical treatment and distillation Th, Ra Accumulates in chlorinator brickwork, radioactive; causes disposal difficulties In the prior art synthetic rutile has been formed from titaniferous minerals, e.g. ilmenite, via various techniques.

According to the most commonly applied technique, as variously operated in Western Australia, the titaniferous WO 94/04709 PCT/AU93/00414 4 mineral is reduced with coal or char in a rotary kiln, at temperatures in excess of 1100 C. In this process the iron content of the mineral is substantially metallised. Sulpbhur additions are also made to convert manganese impurities partially to sulphides. Following reduction the metallised product is cooled, separated from associated char, and then subjected to aqueous aeration for removal of virtually all contained metallic iron as a separable fine iron oxide. The titaniferous product of separation is treated with aqueous sulphuric acid for dissolution of manganese and some residual iron. There is no substantial chemical removal of alkali metals or alkaline earths, aluminium, silicon, vanadium or radionuclides in this process as disclosed or operated. Further, iron and manganese removal is incomplete.

Recent disclosures have provided a process which operates reduction at lower temperatures and provides for hydrochloric acid leaching after the aqueous aeration and iron oxide separation steps. According to these disclosures the process is effective in removing iron, manganese, alkali and alkaline earth impurities, a substantial proportion of aluminium inputs and some vanadium as well as thorium. The process may be operated as a retrofit on existing kiln based installations. However, the process is ineffective in full vanadium removal and has little chemical impact on silicon.

In another prior art invention relatively high degrees of removal of magnesium, manganese, iron and aluminium have been achieved. In one such process ilmenite is first thermally reduced to substantially complete reduction of its ferric oxide content without substantial metallisation), normally in a rotary kiln. The cooled, reduced product is then leached under 35 psi pressure at 140-150 C with excess hydrochloric acid for removal of iron, magnesium, WO 94/04709 PCT/AU93/00414 aluminium and manganese. The leach liquors are spray roasted for regeneration of hydrogen chloride, which is recirculated to the leaching step.

In other processes the ilmenite undergoes grain refinement by thermal oxidation followed by thermal reduction (either in a fluidised bed or a rotary kiln). The cooled, reduced product is then subjected to atmospheric leaching with excess hydrochloric acid, for removal of the deleterious impurities. Acid regeneration is also performed by spray roasting in this process.

In all of the above mentioned hydrochloric acid leaching based processes impurity removal is similar. Vanadium, aluminium and silicon removal is not fully effective.

In yet another process ilmenite is thermally reduced (without metallisation) with carbon in a rotary kiln, followed by cooling in a non-oxidising atmosphere. The cooled, reduced product is leached under 20 30 psi gauge pressure at 130 0

C

with 10 60% (typically 18 25%) sulphuric acid, in the presence of a seed material which assists hydrolysis of dissolved titania, and consequently assists leaching of impurities. Hydrochloric acid usage in place of sulphuric acid has been claimed for this process. Under such circumstances similar impurity removal to that achieved with other hydrochloric acid based systems is to be expected.

Where sulphuric acid is used radioactivity removal will not be complete.

A commonly adopted method for upgrading of ilmenite to higher grade products is to smelt ilmenite at temperatures in excess of 1500 0 C with coke addition in an electric furnace, producing a molten titaniferous slag (for casting and WO 94/04709 PCT/AU93/00414 6 crushing) and a pig iron product. Of the problem impurities only iron is removed in this manner, and then only incompletely as a result of compositional limitations of the process.

In another process titaniferous ore is roasted with alkali metal compounds, followed by leaching with a strong acid other than sulphuric acid (Australian Patent No. AU-B- 70976/87). According to this disclosure substantial removal of various impurities is achieved, with "substantial" defined to mean greater than 10%. In the context of the present invention such poor removal of impurities, especially of thorium and uranium, would not represent an effective process. No specific phase structure after roasting is indicated for this process but it is evident from analytical results provided (where product analyses, unlike feed analyses do not sum to 100% and analyses for the alkali metal added are not given) that there may have been significant retention of the additive in the final product. Under the conditions given it is herein disclosed that it is to be expected that alkali ferric titanate compounds which are not amenable to subsequent acid leaching will form. The consequent retention of alkali will render the final product unsuitable as a feedstock for the chloride pigment process.

In yet another process a titaniferous ore is treated by alternate leaching with an aqueous solution of alkali metal compound and an aqueous solution of a mineral auid (US Patent No. 5,085,837). The process is specifically limited to ores and concentrates and does not contemplate prior processing aimed at artificially altering phase structures.

Consequently the process requires the application of excessive reagent and harsh processing conditions to be even partially effective and is unlikely to be economically

I

7 implemented to produce a feedstock for the chloride pigment process.

A wide range of potential feedstocks is available for upgrading to high titania content materials suited to chlorination. Examples of primary titania sources which cannot be satisfactorily upgraded by prior art processes for the purposes of production of a material suited to chlorination include hard rock (non detrital) illuminates, siliceous leucoxenes, many primary (unweathered) ilmenites and large anatase resources.

Many such secondary sources titania bearing slags) also exist.

Clearly there is a considerable incentive to discover methods for upgrading of titaniferous materials which can economically produce high grade products almost irrespectively of the nature of the impurities in the feed.

The present invention provides a combination of processing steps which may be incorporated into more general processes for the upgrading of titaniferous materials, rendering such processes applicable to the 25 treatment of a wider range of feeds and producing higher

S..

quality products than would otherwise be achievable.

Accordingly, the present invention provides a process for upgrading a titaniferous material by removal of impurities which process includes the steps of:heating the titaniferous material to a temperature of less than 1300 0 C to produce a solid titaniferous phase and a H:\Haria\eep\TECHLoGlCAI..4695 .9 .doc 3/04/97

I

8 liquid oxide phase containing impurities; (ii) cooling the solid titaniferous phase and the liquid oxide phase produced in step to form a solidified material comprising the solid titaniferous phase and an impurity bearing phase that is formed from the liquid oxide phase and is leachable in an acid and/or an alkaline leachant; and (iii) leaching the solidified material with an acidic and/or alkaline leachant to leach at least a portion of the impurities from the impurity bearing phase.

It is preferred that the liquid oxide phase be a liquid glassy phase, ie a phase capable of forming a glass phase on cooling.

It is preferred that the liquid glassy phase be a siliceous liquid phase.

0 It is preferred that the impurity bearing phase be a glass phase.

25 It is preferred that the glass phase be a siliceous glass phase.

In order to ensure the formation of the solid titaniferous phase and the liquid oxide phase during the heating step it will normally be necessary to add to the titaniferous material, prior to the heating step, sufficient of a compound or compounds that encourages the formation of the liquid oxide phase. However, in H.\Mari\KeepTECIRNDLOG1CAL.46915.93.doe 3104/97 I I I L~ 8A some cases it will not be necessary since the titaniferous material itself may contain sufficient of such a compound or compounds.

It has been discovered that the process of the invention can remove iron, magnesium and other alkaline earths, alkalis, manganese, silica, phosphorous, al.mina, vanadium, rare earths, thorium and other radioactive elements, which impurities for.m an almost comprehensive list of impurities in titaniferous mineral sources.

From most materials a product purity of greater than 96% TiO 2 can be obtained.

Compounds added to the titaniferous material may be mixed therewith by any means ranging from direct mixing of additives prior to charging to thermal treatment to more complex feed preparations such as the formation of *eo o* *o H :\Maria\Keep\ECHNOLOGICAt..46915.93.doc 3/04/97

I

27/03 '97 THU 15:53 FAX 61 3 9243 8334 GRIFFITH IACK I007 -9agglomerates of nodules of mixed products, to briquette production from feeds and additives. Many additives will be effective. In particular it is herein disclosed that sodium, potassium, lithium, phosphorus, silicon and boron compounds and minerals borax, trona and other alkali metal carbonates, spodumene, caustic soda) will be effective. Additives may be incorporated individlially or in combination with other additives.

It is further disclosr-d herein that the formation of a liquid oxide phase by addition of alkali compounds can be achieved without the formation of alkali titanate phases, reduced alkali titanate phases NaTiO 2 compounds and solid solutions) or alkali ferric titanate phases Na(Fe, AI)O 2 TiO2 phases known as "bronzes") in roasting. Where such titanate phases form their stability with respect to subsequent leaching steps is such that the final product quality is adversely affected. The incorporation of sufficient quantities of further additives boron or phosphorus compounds) which substantially reduce alkali oxide chemical activity can have the effect of eliminating these phases.

Under many circumstances it will be beneficial to incorporate multiple additives into the material to be treated by thermal processing. For example, it is herein disclosed that the simultaneous presence of silica, anhydrous borax and sodium oxide in 1000'C thermally processed material in weight ratios of about 7:1:1 ensures the preferential formation of a liquid oxide phase over other phases containir.g silica or soda.

In this formulation the tequired borax addition is only just over 10% of the addition which would be required for an equivalent amount of'liquid oxide phase where H1N\¢h.11-YNXM.S;14f i. 9 d.6 17/0319g7 27o. '07 T11 15:54 FAX 01 3 0243 8334 GRIT11 IIACh (Aj Q a I0 other additives do not act as extenders. Since borax is by far the most expensive additive of the three additives in this case optimum economics are achieved by the use of the extenders. Thermal processing may be carried out in any suitable device. The production of liquid phases would recommend rotary or grate kilning, but snaft surfaces may also be used and it has been found that fluidised beds can be used under some circumstances. Any gaseous atmosphere conditions may be used, from fully oxidising to strongly reducing. The thermal processing atmosphere should be chosen to most suit other steps in itegrated processing.

Reducing conditions may be achieved where desired by either the use of a sub stoichiometric firing flame or the addition of coal, char or coke with the thermal processing charge.

Thermal processing residence time at temperature will depend on the nature of the additives and the feed, as well as the operating temperature. Residence times of from 5 minutes to five hours have been effective, allowing thermal processing.residence times to be set to most suit other requirements in integrated processing.

The level of additive used and the conditions applied in thermal orocessing should be such that liquid oxide phase formation does not exceed the limitations set by materials handling constraints in the thermal processing step. For example, where liquid oxide phase formation exceeds about 15% by volume of the roasted material it must be anticipated that accretion and bed fusion problems will occur.

Cooling of the thermally treated material should be Ht \Cihe LeyM4.p 46913,93. doe 27I/O3/97 27'0sb '07 Fflt 10.154 VAX 61 3 0243 8334 GRWVV11I HACK j00 conducted in such a manner as to limit tti., formatlon of crystalline phases from the liquid oxide phase, i.e.

should be at a sufficient rate to a temperature at which the liquid oxide phase solidifies as totensure the formation of at least a portion of solid glass rather than complete formation of cystalline products.

HICftSU*y K*QPi46P13.P3.OOG 2710191 WO 94/04709 PCT/AU93/00414 11 Further, cooling should be conducted under an environment appropriate to the conditions of thermal treatment (i.e.

reduction processing will require cooling in an oxygen free environment).

The aqueous leaching step need not necessarily follow directly after the presently disclosed thermal processing step. For example if the thermal processing step is conducted under oxidising conditions it may be optionally followed by a reduction step prior to aqueous leaching. Further, crushing/grinding of the thermally processed material to enhance subsequent leach performance may be undertaken.

The conditions necessary to conduct effective leaching will depend on the nature of the original feed and the additives.

For example, addition of soda ash and borax to siliceous leucoxene in accordance with the present disclosure will result in a product which can be leached in sodium silicate solution formed directly from the thermally treated material; the active leachant in this case is simply water. In other cases up to 100 gpL caustic soda solution or acid will be an effective leachant. Leaching will generally benefit substantially by use of high temperature 80°C or above), although it has not been necessary to use pressure leaching to achieve effective conditions. Nevertheless it is presently disclosed that pressure leaching can be effectively and successfully applied. Lower temperatures can also be used, although with penalties in process kinetics.

Leaching may be conducted in any circuit configuration, including batch single or multiple stage leaching, continuous cocurrent multistage leaching, continuous countercurrent multistage leaching. For most circumstances two stage cocurrent leaching will be most beneficial. Average residence WO 94/04709 PCT/AU93/00414 12 time may vary from 30 minutes to 10 hours, depending on process conditions. Any leach vessel capable of providing adequate shear may be used. Simple stirred tank vessels are applicable.

At the conclusion of leaching the leach liquor may be separated from the mineral by any suitable means, including thickening, filtration and washing. The mineral product may then pass on to other steps in an integrated process. For example, a further acid leach may follow the disclosed leaching step, particularly where the titaniferous feed has a content of alkalis or alkaline earths.

Other processing steps may be added as necessary or desired.

For example, reagent regeneration caustic regeneration, hydrochloric acid regeneration, sulphuric acid regeneration) can be used with the process in order to improve process effectiveness or economics. Similarly, a physical separation step may be employed at any stage a final magnetic separation to remove grains containing iron, such as chromite).

Examples Example 1 Sodium carbonate addition, corresponding to 4.25% Na,0 by weight, was made to a titania concentrate whose composition is given in Table 1. The mixture was homogenised and pelletised, and the pellets were heated in air to 1000C for 4 hours. The thus roasted pellets were quenched in liquid nitrogen and then crushed to pass a screen of 200 microns aperture. The crushed roasted pellets were subjected to leaching under reflux with 40 wt% sodium silicate solution (Si0 2 :Na,0=2,4:1 by weight) at 4% slurry density. (Sodium silicate solution was used to simulate leaching using water I S WO 94/04709 PCT/AU93/00414 13 as leachant under conditions where the leach liquors are recycled to leaching after solid/liquid separation).

Solid/liquid separation was effected by centrifuging, after which the leach residue was washed and calcined at 1000C0 for analysis. The analysis of the calcined product is also given in Table 1.

The original concentrate was known to contain silica primarily as quartz inclusions in titanate grains. X-ray diffraction analysis after roasting indicated extinction of all crystalline phases containing silica. A glassy phase containing 16% NaO0, 46% SiO 2 9% A1,0 3 26% Tio, and 3% Fe20 3 was identified in the roasted material by electron microscopy. Sodium titanates and sodium iron titanium bronze were also identified (along with rutile) by these techniques, indicating that conditions were not optimised.

Nevertheless, highly effective concentrate upgrading has been achieved even where the benefits of subsequent acid leaching have not been pursued, illustrating the benefits of the formation of the glassy phase. Substantial removal of silica, alumina and vanadium was achieved.

Example 2 This example illustrates the optimisation of additives for both process effectiveness and most economic formulation.

In this example titania concentrates of the composition given in Table 2 were used as titaniferous material for treatment.

Early work attempting to produce glassy phase with this material by addition of sodium carbonate prior to roasting indicated that glassy phase could easily be produced, but over a wide range of conditions reduced sodium titanate or SWO 94/04709 PCT/AU93/00414 14 sodium iron titanate bronze formation which resulted in sodium retention after leaching could not be easily avoided.

Complete and partial replacement of sodium carbonate by borax was tested.

Two batches of hand pressed pellets were prepared as follows.

A 100g sample of the concentrates (previously ground to passing a screen aperture of 30 microns) was blended in each case with 1.1% of the appropriate additive or additive mixture and the resulting blends were pressed into pellets.

The first batch was prepared with 1.1 wt% of anhydrous borax addition while the second batch was prepared with addition of 1.1 wt% of 1 1 NaB 4 0,:NaO.

Each batch of pellets was roasted for two hours in a 7 1 H,/CO, atmosphere at 1000 0 C and then removed to cool quickly in the same atmosphere. The roasted pellets were ground to pass a screen aperture of 75 microns for subsequent leaching.

Ground roasted pellets were caustic leached under reflux conditions for 6 hours in a 10% NaOH solution at 6.7% solids density. Solid/liquid separation was effected by filtration, and the caustic leached products were washed and dried in preparation for subsequent acid leaching.

The ca-'stic leached residues were acid leached in 15% HC1 for 4 hours under reflux, then similarly filtered, washed and dried.

In each case samples of the concentrate and roasted material were submitted for X-ray diffraction analysis. While quartz and various ilmenite, anatase and rutile related phases were identified in the concentrates the only crystalline phases identified in the roasted product were rutile and ilmenite.

WO 94/04709 PCT/AU93/00414 All quartz had entered a glassy phase, and no titanate phases which would reduce leach effectiveness were identified.

Analyses of the caustic and acid leach residues in each case, illustrating the effectiveness of the process where optimum conditions are applied, are provided in Table 3.

Example 3 The same pellet formulations as indicated in Example 2 were made up in 350 kg batches in an agglomeration plant and roasted at 30 kg/hr feed rate with 15% brown coal char addition to a final temperature of 1000 0 C in a small diameter) rotary kiln. Residence time above 900 0 C was approximately 10 minutes. There were no problems with accretions or bed fusion, and after separation from residual char the products had exactly the same properties as the roasted products of Example 2.

Example 4 A dommercial titania slag product having the composition indicated in Table 4 was processed as for the processing conditions indicated in Example 2, but with 2 wt% anhydrous borax addition in place of the other additives. The caustic leach was conducted at 165 0 C under pressure, and a pressure leach with 20% sulphuric acid conducted at 135 0 C was used in place of the hydrochloric acid leach. The final residue was calcined at 900 0 C for one hour. The products of this treatment are indicated in Table 4.

Example This example when compared with examples 1 and 2 illustrates the advantages of the formation of a glassy phase.

Concentrates having the composition indicated in Table 3 were

I

j I, WO 94/04709 PCT/AU93/00, 16 subjected leaching under atmospheric reflux conditions with excess 20% HC1. After separation of the residue from the liquor followed by washing and drying of the residue its composition was as given in Table 5. Clearly there was ineffective removal of virtually all impurities of interest by comparison with the other examples provided herein.

Table 1: Concentrates and Product from Example 1 wt% Concentrate Product TiO 2 85.8 94.9 Fe 2 0 3 2.25 1.91 A1 2 0 3 1.08 0.63 SiO 2 7.62 0.74 0.30 0.31

V

2 0 5 0.235 0.02 NaO2 0.0 1.10 Table 2: Composition of Concentrates Used in Examples 2 and 3 wt% TiO 2 63.6 Fe 2 0 3 28.6 Si02 3.53 Al 2 0 3 0.80 MgO 0.87 CaO 0.02 0.55 MnO 1.11

V

2 0 5 0.22 ZrO 2 0.26 POs 0.04

U

3 0 0.002 ThO, 0.01 WO 94/04709 WO 94/4709 IC'r/AtJ93/004 14 17 Table 3: Compositions of Leach Products from Example 2 1. 1% Na 2

B

4

O,

addition Causti' Acid Leach Wt96 1.1% 1:1 addition Caustic Leach Residue Na 2

B

4

O

7 Na 2

O

Acid Leach Residue TiO 2 Fe 2 0 3 Si0 2 A1 2 0 3 MgO CaO Cr 2 0 3 MnO

V

2 05 Zr0 2 Na 2 0

P

2 0 5 Th0 2 Leach Residue 66.9 27.1 1.12 0.22 0.97 0.05 0.68 1.15 0.22 0.27 0.05 0 .02 0 .002 Residue 94.3 30.2 0.99 0.17 0.08 0.001 0.69 0.06 0.15 0.37 0.02 0.02 0 .002 67.3 30.6 0.55 0.14 0.90 0.03 0.70 1.19 0.23 0.28 0.15 0 .01 0 .002 94.9 2.04 0.86 0.15 0 .09 0.001 0.67 0.06 0.13 0.38 0 .03 0 .02 0 .002 0.004 0.01 0.003 0.01 WO 94/04709 PCT/AU93/0041 4 Table 4: Feed and Product in Example 4 wt96 TiO 2 FeO SiO 2 A1 2 0 3 MgO CaO Cr 2 0 3 MnO

V

2 0 5 Zr0 2

P

2 0 5

U

3 0 8 ThO 2 Commercial Slag 79.7 9.24 3.11 3.23 4.81 0.41 0.16 0.25 0.57 0.046 0 .002 0.0005 0.0006 Roast/Leach Product 97.2 0.85 0.09 0.38 0.43 0.002 0.12 0.02 0.12 0.06 0 .004 n.d.

n.d.

n.d. not determined Table 5: Wt%6 Ti 02 Fe 2 0 3 SiO 2 A1 2 0 3

V

2 05

U

3 08 ThO 2 Results of Processing as described in E~xample Leach Product P88.6 0.98 7.54 0.65 0.198 0.0054 0.0094

Claims (26)

1. A process for upgrading a titaniferous material by removal of impurities which process includes the steps of: heating the titaniferous material to a temperature of less than 1300°C to produce a solid titaniferous phase and a liquid oxide phase containing impurities; (ii) cooling the solid titaniferous phase and the liquid oxide phase produced in step to form a solidified material comprising the solid titaniferous phase and an impurity bearing phase that is formed from the liquid oxide phase and is leachable in an acid and/or an alkaline leachant; and (iii) leaching the solidified material with an *i i 20 acidic and/or alkaline leachant to leach at least a portion of the impurities froum the impurity bearing phase. 0"

2. A process according to claim 1, wherein the 25 liquid oxide phase is a liquid glassy phase as described herein.

3. A process according to claim 2, wherein the liquid glassy phase is a siliceous liquid phase.

4. A process according to any one of the preceding claims, wherein the impurity bearing phase formed in step (ii) is a glass phase.

Hl\HNria\Ketp\TECHNOLOGILCAL.46915,93.doc 3/04/97 I 20 A process according to claim 4, wherein the impurity bearing phase formed in step (ii) is a siliceous glass.

6. A process according to any one of the precedirg claims, wherein step comprises heating the titaniferous material in the presence of one or more compounds which encourage the formation of the liquid oxide phase.

7. A process according to claim 6, wherein the compound or compounds which encourage the formation of the liquid oxide phase are a compound or compounds of sodium, potassium, lithium, aluminium, phosphorus, silicon or boron.

8. A process according to claim 7, wherein the compound or compounds which encourage the formation of 20 the liquid oxide phase including caustic soda. S q..

9. A process according to claim 7, wherein the compound or compounds which encourage the formation of the liquid oxide phase include sodium carbonate. **o

10. A process according to claim 7, wherein the S* compound or compounds which encourage the formation of the liquid oxide phase include alkali metal carbonates.

11. A process according to claim 7, wherein the compound or compounds which encourage the formation of the liquid oxide phase include silica or silicates. H:\Mara\eer\ECINOLDtoCAL.46915.93.doc 3/04/97 I C 1

12. A process according to claim 7: wherein the compound or compounds which encourage the formation of the liquid oxide phase include borax.

13. A process according to claim 7, wherein the compound or compounds which encourage the formation of the liquid oxide phase include soda ash and borax.

14. A process according to any one of the preceding claims, wherein step comprises heating the titaniferous material unde. xecucing conditions.

A process according to claim 14, wherein the reducing conditions comprise heating the titaniferous material in the presence of a solid carbonaceous material.

16. A process according to claim 15, wherAin step comprises heating the titaniferous ma',.rial to a 20 minimum temperature of 1000°C for a period which avoids substantial reduction to metal of metal oxides in the titaniferous material.

17. A process according to any one of the preceding 25 claims, wherein step comprises heating the .titaniferous material to a temperature of at least 1000 0 C.

18. A process according to claim 6 comprises adding the compounds which encourage the formation of the liquid oxide phase in an amount that is sufficient to minimise the formation of tita.late phases that are not amendable to subsequent leaching. 'I I \r ia\Keep\TECIINOLOG ICAL. 4 6915.93.doc J/04/97 M 22

19. A process according to claim 1, wherein step (i) comprises heating the titaniferous material to a minimum temperature of 1000°C under conditions which avoid substantial reduction to metal of iron oxides in the titaniferous material.

A process according to any one of the preceding claims, wherein step (iii) consists of forming the leachant by the addition of water.

21. A process according to any one of claims 1 to 19, wherein step (iii) comprises leaching the solidified material with a recycled solution of leach liquor containing sodium silicate and borax to form a leachate and a residue. i*

22. A process according to claim 21 further comprises separating the leachate from residue and 20 leaching the residue with hydrochloric acid having an aci'" strength in a range from 1 to 20 wt% hydrochloric acid.

23. A process according to any one of claims 1 to 25 19, wherein step (iii) comprises leaching the solidified material with the alkaline leachant.

24. A process according to claim 23 further comprises leaching the alkaline leached solidified material with an acidic leachant.

A process according to any one of the preceding claims comprises leaching the solidified material at Htt\Mar:.\Keep\ T.CHNOLOICAt.4691t.93.doC 3/4/91 mI 23 atmospheric pressure.

26. An upgraded titaniferous material produced by the process of any one of the preceding claims. Dated this 3 rd day of April 1997 TECHNOLOGICAL RESOURCES PTY LTD By Its Patent Attorneys GRIFFITH HACK Fellows Institute of Patent Attorneys of Australia *l *o o *o o*o It i NHA r I A\K0ePTECJC-TtA)G% 4 615.9dde 3104197 31 ABSTRACT The application discloses a process for upgrading a titaniferous material by removal of impurities contained in the material especially radionuclides. The process involves heating the titaniferous material to a temperature of less than 1300 0 C to form a solid titaniferous phase and a liquid oxide phase containing impurities in the presence of a material that promotes the formations of such phases, cooling the product to form a solidified material comprising the solid titaniferous phase and an impurity bearing phase and leaching the solidified material with an acid or an alkali to remove the impurities. Materials that promote the formation of the desired 20 phases include compounds of alkali metals and boron. Examples include borax, caustic soda, soda ash and oe@@ silica. o...o *b* oo o o, It:\\ara\eep\1ECaOWLdZCAL. 46915.93.& 3104/91 *l TERNATIONAL SEARCH REPORT International application No. PCT/AU 93100414 A. CLASSIFICATION OF SUBJECT MATTER Int. Cl. 5 C22B 1/00, 1/02 C22B 34112 According to International Patent Classification (IPC) or to both national classification and IPC B. FIELDS SEARCIIED Minimum documentation searched (classification system followed by classification symbols) IPC C22B 1/00, 1/02, 34/12, 53/00 Documentation searched other than minimum documentation to the extent that such documents are :ncluded in the fields searched AU IPC as above Electronic data base consulted during the international search (name of data bare, and where practicable, search terms used) C. DOCUMENTS CONSIDERED TO BE RELEVANT Category Citation of document, with indication, where appropriate, of the relevant passages Relevant to Claim No. AU,A, 70976/87 DU PONT DE NEMOURS CO) 8 October 1987 (08.10.87) X Page 2 line 25 page 3 line 10 age 8 line 7 page 10 line 13 1-4,13-16 AU,A, 46046/93 (WIMMERA INDUSTRIAL MINERALS PTY LTD) 18 November 1993 (18.11.93) P,X Example 9 1,2,4,13-16 AU,A, 44589/93 (WIMMERA INDUSTRIAL MINERALS PTY LTD 11 November 1993 (11.11.93) P,X Example 9 1,2,4,13-16 S Further documents are listed X See patent family annex. in the continuation of Box C. Special categories of cited documents later document published after the international filing date or pnority date and not in conflict document definin the eneral state of the art which is with the application ut cited to understand the not considered to be oparticular relevance principle or theory underlying the invention earlier document but published on or after the document of particular relevance; the claimed international filing date invention cannot be considered novel or cannot be document which may throw doubts on priority claim(s) considered to involve an inventive step when the or which is cited to establish the publication date of document is taken alone another citation or other special reason (as specified) document of particular T-levance; the claimed document referring to an oral disclosure, use, invention cannot be considered to involve an exhibition or other means inventive step when the document is combined document published prior to the international filing date with one or more other such documents, such but later than the priority date claimed combination being obvious to a person skilled in the art document member of the same patent family Date of the actual completion of the international search Date of mailing of the international search report 18 November 1993 (18.11.93) g AO 1V /199 (22. Name and mailing address of the ISA/AU Authorized officer AUSTRALIAN INDUSTRIAL PROPERTY ORGANISATION PO BOX 200 WODEN ACT 2606 AUSTRALIA VIVIENNE THOM Facsimile No. 06 2853929 Telephone No. (06) 2832158 Form PCT/ISA/210 (continuation of first sheet (July 1992) copjne L a INTERNATIONAL SEARCH REPORTInraioaaplcioNo PCTIAU 93/00414 C(Continuation). DOCUMENTS CONSIDERED TO BE RELEVANT Category* Citation of documient, with indication, where appropriate of the relevant passages AU,A, 74507/9 1 (WMMERA INDUSTRIAL MINERALS PTY LTD) September 1991 (05.09.91) X Page 4 lines 17-34, page 8 line 31 page 9 line 4 US,A, 2815272 (ARMANT et al) 3 December 1957 (03.12.57) X Claim 1 AU,A, 14981/92 (ROC MINERAL SANDS LIMITED) 22 September 1992 (22.10.92) A Claim 1 Relevant to Claim No. 1, 14-16 1-4,14-16 J J Form PCTIISAI2IO (continuation of second sheet)(July 1992) copjnc SINTERNATIONAL SEARCH REPORT Information on patent family mcml International application No, PCT/AU 93/00414 This Annex lists the known publication level patent family members relating to the patent documents cited in the above-mentioned international search report. The Australian Patent Office is in no way liable for these particulars which are merely given for the purpose of information. Patent Document Cited in Search Patent Family Member Report AU 70976/87 BR 8701481 EP 243725 ZA 8702399 AU 74507/91 BR 9106105 CA 2077441 EP 517786 NZ 237273 WO 9113180 ZA 9101515 AU 14981/92 BR 9201442 JP 5180989 END OF ANNEX Form PCT/ISA/210(patent family annex)(July 1992) copjne