Titania slag is a feedstock to the pigment industry, which in turn provides titania pigment to producers of everyday products like paper, cosmetics and toothpaste. Titania slag is the primary product of the pyrometallurgical process of ilmenite smelting – the other products being iron and CO gas. Titania slag is typically tapped from the furnace into blocks of approximately 20 tons. After cooling these blocks are crushed and milled to size fractions suitable for the processes of the pigment producers. These processes are broadly grouped into two types of technology: the chloride route (during which titania slag is reacted with chlorine and subsequently re oxidised thereby removing the impurities) and the sulphate route (in this process the titania slag is purified after dissolving the slag in sulphuric acid). Due to the nature of these two processes, several specifications are imposed on the quality of the titania slags. The fluidised-bed technology used in the chloride process limits the size distribution of the slag to between 106 µm and 850 µm. Ilmenite smelting industries consequently crush and mill the titania slag to below 850 µm. The fraction below 106 µm is then sold to the sulphate market. Since the coarser chloride grade product is the more valuable product, slag producers continuously strive to improve the ratio between the coarser and finer fractions. This study reports on parameters which influence the particle size distribution of titania slags and therefore the split between the coarser (more valuable) and finer (less valuable) products. Pilot-scale slag ingots were used to identify chemical and process variables which influence the yield of coarser material. The microstructure of as-cast and milled slag was examined, and indicated a role of silicate phases in the crushing behaviour. Industrial-scale slag ingots were used to test whether the roles of tapping rate and water cooling (as identified from the pilot-scale ingots) also applied under industrial conditions. A numerical method was applied to estimate the thermal conductivity of the solidified slag (from measurements on pilot-scale ingots), and to predict the cooling and solidification behaviour of industrial-scale ingots. The study concludes that the chemical composition and cooling conditions of the slag block play central roles in the final particle size distribution of the slag. / Thesis (PhD (Metallurgical Engineering))--University of Pretoria, 2009. / Materials Science and Metallurgical Engineering / unrestricted

Thesis (Ph. D.)(Metallurgical Engineering)--University of Pretoria, 2004. / Title from opening screen (viewed March 14, 2005). Summaries in English and Afrikaans. Includes bibliographical references.

Please read the abstract in the section 00front of this document Copyright 2000, University of Pretoria. All rights reserved. The copyright in this work vests in the University of Pretoria. No part of this work may be reproduced or transmitted in any form or by any means, without the prior written permission of the University of Pretoria. Please cite as follows: Bessinger, D 2000, Cooling characteristics of high titania slags, MSc dissertation, University of Pretoria, Pretoria, viewed yymmdd < http://upetd.up.ac.za/thesis/available/etd-07212006-102324 / > H 95 / Dissertation (MSc (Metallurgy))--University of Pretoria, 2007. / Materials Science and Metallurgical Engineering / unrestricted

This study focused on the dynamic behaviour of the freeze lining and slag bath, and the interactions between these components in an ilmenite-smelting furnace process. The purpose of the work was to gain a better understanding of these issues and to ultimately contribute to an improved understanding of the ilmenite-smelting process in its entirety, and to future improvements in the design, operation and control of these processes. A mathematical model of the freeze lining and furnace sidewall was developed. This model was used in isolation for focused characterisation of the dynamic behaviour and interactions of the freeze lining and slag bath. The influences of net power input and slag composition were studied and various aspects of the freeze lining and slag bath were considered. These aspects included freeze lining thickness, temperature distribution through the freeze lining and furnace sidewall, composition distribution through the freeze lining, slag bath temperature and slag bath composition. The thermal response of thermocouples installed in the furnace sidewall to changing conditions on the inside of the furnace was also investigated. A mathematical model of the crust that forms on the slag bath surface was developed. This model was not used in isolation, and was only incorporated into a complete model of the process. A mathematical model of the entire ilmenite-smelting furnace process was constructed. This model incorporated the two models mentioned above and was able to describe the metal bath, slag bath, furnace atmosphere, freeze lining, furnace sidewall and the crust that is sometimes present on top of the slag bath. The model was used to study the influence of changes in operational parameters on the slag bath and freeze lining. The operational parameters that were studied included electrical power and reductant feed rate, both relative to ilmenite feed rate. The influence of severe operational errors and furnace down time were also investigated. Operational errors included loss of all feed while maintain electrical power input, and loss of reductant feed while maintaining power input and ilmenite feed. The above-mentioned studies were conducted by executing numerous experiments with two of the mathematical models. The experimental results were processed into sets of graphs displaying variations in the aspects that were considered. Many valuable insights resulted from the interpretation of these results. One specific aspect that formed part of the scope of this work was the origin of the compositional invariance of the slag close to the stoichiometric M3O5composition. This invariance was studied and a mechanism was proposed that explains the observed behaviour. The proposed mechanism created some questions about other mechanisms in the process. These mechanisms were also considered and elaborated on. The models and results produced in this study provide valuable insights into the behaviour of the ilmenite-smelting process. It also represents a useful foundation for future modelling work, and finally, it presents numerous opportunities for organisations operating ilmenite-smelting furnaces to improve their understanding and even the performance of their processes. / Thesis (PhD (Metallurgical Engineering))--University of Pretoria, 2004. / Materials Science and Metallurgical Engineering / unrestricted