Pyroelectrometallurgical processing of bismuth-containing oxides

In this work, we substantiate and develop a general pyroelectrometallurgical technology for processing bismuth dross and oxides (the intermediate products of lead bullion refining by the Betterton-Kroll process) to obtain crude bismuth. The research focuses on bismuth dross (3–5% Bi; 80–85% Pb) remelted at 500–600°С in the presence of NaNO3 and NaOH, as well as the obtained alkaline melt (bismuth oxides, 1–5% Bi; 60–70% Pb). The conducted experiments allowed us to determine optimal parameters of the main steps of processing bismuth oxide, as well as the characteristics of obtained products. Reduction smelting of bismuth oxides at 1150°C (with the addition of sodium carbonate, quartz and fine coke in the amount of 66, 25 and 5% of bismuth oxides mass, respectively) is proposed, leading to bismuth lead formation. Its decoppering is carried out at 350–600°C with 2.0% sulfur (by its weight), added to the melt. We propose to carry out the alkaline treatment of the decoppered Pb-Bi alloy at 500oC in contact with sodium hydroxide, sodium nitrate and sodium chloride, taken in amounts up to 10.2, 8.3 and 1.4% by weight of bismuth lead, respectively. Subsequent electrolysis comprises electrolytic processing of purified Pb-Bi alloy ingots at 550oC. The electrolyte consists of a melt with the following composition, %: NaCl – 7, KCl – 35, PbCl2 – 18 and ZnCl2 – 40. As a result, two end products were obtained by the proposed bismuth oxide processing. The anodic product at the second stage of electrolysis, crude bismuth (yielded 1.1% by the weight of oxides) contains 93.62% Bi and 4.14% Pb, extraction from oxides amounts to 19.0% Bi and 0.1% Pb. About 1.2% Bi and 9.1% Pb of their initial content in the oxides are transferred to the cathodic product containing 0.033% Bi and 97.83% Pb (the yield equalled 5.1% of the oxides).

Titanium: An Overview of Resources and Production Methods

For several decades, the metallurgical industry and the research community worldwide have been challenged to develop energy-efficient and low-cost titanium production processes. The expensive and energy-consuming Kroll process produces titanium metal commercially, which is highly matured and optimized. Titanium’s strong affinity for oxygen implies that conventional Ti metal production processes are energy-intensive. Over the past several decades, research and development have been focusing on new processes to replace the Kroll process. Two fundamental groups are categorized for these methods: thermochemical and electrochemical. This literature review gives an insight into the titanium industry, including the titanium resources and processes of production. It focuses on ilmenite as a major source of titanium and some effective methods for producing titanium through extractive metallurgy processes and presents a critical view of the opportunities and challenges.

Inflow process of Fe, Ni, and Cr impurities in Ti sponge during kroll process

To produce Ti sponge for aerospace applications, the inflow process of Fe, Ni, and Cr impurities has been investigated by obtaining the distribution of the concentrations of these impurities, analyzing the microstructure and elemental composition of specimens, and calculating the formation enthalpies of the Mg–Ti–Fe, Mg–Ti–Ni and Mg–Ti–Cr ternary systems via the Miedema and Troop models. Fe, Ni, and Cr impurities are heterogeneous enriched, and the sides of the sponge mass have relatively higher impurity contents. This is caused by contamination from the stainless-steel reaction retort. The inflow process of impurities consists of two steps: the dissolution of impurities in liquid Mg and the formation of alloys with the Ti sponge. The retort material, the temperature of the reaction zone, and the uniformity and thickness of the Ti film are the key factors that directly influence the impurity contents.

Optimization of electroslag melting towards to titanium morphology improvement in combined Kroll process

Purpose The paper aims to optimize calcium difluoride electrical melting process towards creating titanium production with improved morphology by combining titanium reduction and electroslag melting processes. The study aims to explore optimal electrical heating power in the slag supplied via tungsten electrode and formation of a stable skull layer on water-cooled walls of a cylindrical stainless steel reactor, which is crucial for electroslag melting. Design/methodology/approach The multi-physical numerical modelling approach using commercial software COMSOL Multiphysics is presented in the paper by coupling electrical, heat transfer and fluid flow problems. The slag material phase change and corresponding changes of physical properties such as electrical conductivity and viscosity are modelled by step function, sharply changing value of parameter near the phase change temperature. A parametric study of applied electrical power has been carried out to find optimal conditions for the skull-layer formation. Findings The paper provides an estimation of necessary electrical power to avoid overheating or solidification of the top layer of slag, which is unacceptable for the combined Kroll process. The study also revealed important poloidal buoyancy flow with characteristic velocity of few cm/s of in the reactor, which governs the heat transfer process and formation of the skull layer. Research limitations/implications The presented simplification in numerical model offers high calculation speed but lacks fully developed phase change model, e.g. excluding latent heat. Also, heat transfer through radiation is neglected in the model. Originality/value The paper presents an original way to overcome the complexity of modelling slag electrical melting/solidification phenomena using temperature-dependent properties with step functions.

Titanium production by magnesium thermal reduction in the electroslag process

Titanium is widely used in specific applications due to its high strength, low density and good chemical stability. Despite it is one of the most abundant elements in the earth’s crust, it is very expensive, because production of pure metallic titanium is very complex. Kroll process is the way how most of the titanium is produced nowadays. Shortages of this process are that it is batch process and it is very energy exhaustive, because titanium sponge material after reduction reaction needs complex post processing to isolate pure titanium. In this work we describe and experimentally investigate technology for Ti production from titanium tetrachloride using combined Kroll and electroslag process. Such process allows to achieve better reaction product separation by molten slag and process can potentially be continuous, thus technological process to produce metallic titanium can be significantly shortened.

On Thermodynamic Possibility of Retort Steel Components Interaction with Titanium Chlorides and Oxygen During Kroll Process

Thermodynamic analysis was carried out of the possible effects of interaction reactions of the main components of the metallic retort (Fe, Ni, Cr, Mn) with titanium chlorides and with oxygen, during magnesium thermal method of titanium obtaining. The temperature dependences of DG for the conversion of metals into their chlorides and oxides allowed to establishe the temperature ranges in which the above reactions take place.