Chlorination of ilmenite and the like

Claim 2

A flow process for chlorinating ferruginous titaniferous material having an iron to titanium molar ratio (Fe/Ti) of x:1, x being a positive number having a value of at least about 0.25, for producing titanium chlorides and by-product metallic iron, which comprises passing through a reaction zone maintained at about 1050°-1950° C. in substantially laminar flow a mixture of said titaniferous material in finely-divided form; carbonaceous reductant; and a chlorinating agent selected from the group consisting of chlorine gas, HCL, an organo-chloride, and mixtures thereof; there being not more than (x+2) moles of chlorine provided from said chlorinating agent per gram atom of titanium in said titaniferous material, the atomic ratio of carbon in said mixture to the oxygen content in said mixture being greater than 1:1 for formation of CO, withdrawing from said zone a product stream containing said titanium chlorides comprising TiCl 4 , said by-product metallic iron, carbon monoxide, and iron chlorides comprising FeCl 2 , the molar ratio of chlorine from said chlorinating agent to said titanium in said titaniferous solids (Cl 2 /Ti), said iron to titanium ratio (Fe/Ti) in said titaniferous solids, and said reaction zone temperature being those whereby neither all of said chlorine nor all of said iron in said titaniferous solids is converted into iron chlorides withdrawn from said zone; and separating at least said titanium chlorides and said by-product metallic iron from said product stream.

Claim 3

The process of claim 1 wherein said iron to titanium ratio (Fe/Ti) is between about 0.25:1 and 100:1.

Claim 4

The process of claim 2 wherein said ratio is between about 0.5:1 and 2:1.

Claim 5

The process of claim 1 wherein said reaction zone temperature is between about 1250° and 1750° C.

Claim 6

The process of claim 1 wherein said Fe/Ti ratio is between about 0.5:1 and 2:1 and said Cl 2 /Ti ratio is between about 2:1 and 3.5:1, and said reaction zone temperature is between about 1300° and 1600° C.

Claim 7

The process of claim 1 wherein said Fe/Ti ratio, said Cl 2 /Ti ratio, and said reaction zone temperature are those whereby at least about 75% of said titanium in said titaniferous material is converted into titanium chlorides.

Claim 8

The process of claim 6 wherein said Fe/Ti ratio is between about 0.5:1 and 2:1, said reaction zone temperature is between about 1300° and 1600° C., and said Cl 2 /Ti ratio is between about 2.2:1 and 3.5:1.

Claim 9

The process of claim 1 wherein said chlorinating agent is chlorine gas.

Claim 10

The process of claim 1 wherein said carbonaceous reductant is in finely-divided solid form.

Claim 11

The process of claim 9 wherein the weight concentration of said titaniferous solids and said carbonaceous reductant solids in said inlet gases in said mixture is not substantially greater than about 20 kg/m 3 .

Claim 12

The process of claim 10 wherein said concentration is between about 1.6 and 20 kg/m 3 .

Claim 13

The process of claim 1 wherein said coke is made by coking coal.

Claim 14

The process of claim 1 wherein said titaniferous material is pre-reduced prior to passing it into said reaction zone.

Claim 15

The process of claim 12 wherein said titaniferous material is pre-reduced simultaneously with said coking.

Claim 16

The process of claim 1 wherein said solid titaniferous material and said solid carbonaceous reductant in admixture are pre-heated to a temperature sufficient to maintain said reaction zone at about 1350° to 1950° C.

Claim 17

A flow process for chlorinating ferruginous titaniferous solids having an iron to titanium molar ratio of between about 0.25:1 and 5:1 for producing titanium chlorides and by-product metallic iron, which comprises: passing through a reaction zone maintained at about 1300° to 1600° C. in substantially laminar flow a mixture of said titaniferous solids in finely-divided form; finely-divided solid carbonaceous reductant; and a chlorinating agent selected from the group consisting of chlorine gas, HCl, an organo-chloride and mixtures thereof, there being at least about 2 but not more than 7 moles of chlorine provided from said chlorinating agent per gram-atom of titanium in said titaniferous material, the atomic ratio of carbon in said mixture to the oxygen content in said mixture being greater than 1:1 for formation of CO, withdrawing from said zone a product stream containing titanium chlorides comprising TiCl 4 , said by-product metallic iron, carbon monoxide, and iron chlorides comprising FeCl 2 , the molar ratio of chlorine from said chlorinating agent to said titanium in said titaniferous solids (Cl 2 /Ti), said iron to titanium ratio in said titaniferous solids (Fe/Ti), and said reaction zone temperature being those whereby neither all of said chlorine nor all of said iron is converted into iron chlorides withdrawn from said zone, and separating at least said titanium chlorides and said by-product metallic iron from said product stream.

Claim 18

A flow process for chlorinating ferruginous titaniferous solids having an iron to titanium molar ratio of between about 0.25:1 and 5:1 for producing titanium chlorides and by-product metallic iron, which comprises: passing through a reaction zone maintained at about 1300° to 1600° C. in substantially laminar flow a mixture of said titaniferous solids in finely-divided form; finely-divided solid carbonaceous reductant; and a chlorinating agent selected from the group consisting of chlorine gas, HCl, an organo-chloride and mixtures thereof, there being at least about 2 but not more than 7 moles of chlorine provided from said chlorinating agent per gram-atom of titanium in said titaniferous material, the atomic ratio of carbon in said mixture to the oxygen content in said mixture being greater than 1:1 for formation of CO, withdrawing from said zone a product stream containing titanium chlorides comprising TiCl 4 , said by-product metallic iron, carbon monoxide, and iron chlorides comprising FeCl 2 , the molar ratio of chlorine from said chlorinating agent to said titanium in said titaniferous solids (Cl 2 /Ti), said iron to titanium ratio in said titaniferous solids (Fe/Ti), and said reaction zone temperature being those whereby neither all of said chlorine nor all of said iron is converted into iron chlorides withdrawn from said zone, and separating at least said titanium chlorides and said by-product metallic iron from said product stream.

Claim 19

The process of claim 16 wherein said Cl 2 /Ti ratio, said Fe/Ti ratio, and said reaction zone temperature are those whereby essentially all of said titanium is converted into titanium chlorides.

Claim 20

The process of claim 16 wherein said chlorinating agent is chlorine gas.

Claim 21

The process of claim 18 wherein the weight concentration of said titaniferous solids and said carbonaceous reductant solids in the inlet flow gases in said mixture is not substantially above about 20 kg/m 3 .

Claim 22

A flow process for essentially completely chlorinating the titanium content of ferruginous titaniferous material whereby essentially all the iron content is converted to metallic form which comprises: passing through a reaction zone maintained at about 1350° to 1950° C. in substantially laminar flow a mixture of said titaniferous material in finely-divided solid form and having a molar ratio of iron to titanium (Fe/Ti) of not above 2; carbonaceous reductant; a chlorinating agent selected from the group consisting of chlorine gas, HCl, an organochloride, and mixtures thereof; and iron chlorides recycled from a later step of the process, the molar ratio of said iron chlorides recycled to said titanium (FeCl 2 /Ti) being not substantially above about 1 and the molar ratio of the chlorine in said chlorinating agent to said iron chlorides recycled (Cl 2 /FeCl 2 ) being not substantially less than about 2:1, the atomic ratio of carbon in said mixture to the oxygen content in said mixture being greater than 1:1 for formation of CO, there being no more than about 2 moles of chlorine from said chlorinating agent per gram-atom of titanium in said titaniferous solids, and said Fe/Ti ratio in said titaniferous material and said reaction zone temperature being those whereby the net chlorination of said titanium and reduction of said iron is in a steady-state; withdrawing from said zone a product stream containing titanium chlorides comprising TiCl 4 , by-product metallic iron, carbon monoxide, and iron chlorides comprising ferrous chloride, separating from said withdrawn product stream said iron chlorides, said titanium chlorides, and said by-product metallic iron; and recycling said separated iron chlorides to said reaction zone.

Claim 23

A flow process for essentially completely chlorinating the titanium content of ferruginous titaniferous material whereby essentially all the iron content is converted to metallic form which comprises: passing through a reaction zone maintained at about 1350° to 1950° C. in substantially laminar flow a mixture of said titaniferous material in finely-divided solid form and having a molar ratio of iron to titanium (Fe/Ti) of not above 2; carbonaceous reductant; a chlorinating agent selected from the group consisting of chlorine gas, HCl, an organochloride, and mixtures thereof; and iron chlorides recycled from a later step of the process, the molar ratio of said iron chlorides recycled to said titanium (FeCl 2 /Ti) being not substantially above about 1 and the molar ratio of the chlorine in said chlorinating agent to said iron chlorides recycled (Cl 2 /FeCl 2 ) being not substantially less than about 2:1, the atomic ratio of carbon in said mixture to the oxygen content in said mixture being greater than 1:1 for formation of CO, there being no more than about 2 moles of chlorine from said chlorinating agent per gram-atom of titanium in said titaniferous solids, and said Fe/Ti ratio in said titaniferous material and said reaction zone temperature being those whereby the net chlorination of said titanium and reduction of said iron is in a steady-state; withdrawing from said zone a product stream containing titanium chlorides comprising TiCl 4 , by-product metallic iron, carbon monoxide, and iron chlorides comprising ferrous chloride, separating from said withdrawn product stream said iron chlorides, said titanium chlorides, and said by-product metallic iron; and recycling said separated iron chlorides to said reaction zone.

Claim 24

The process of claim 20 wherein said Fe/Ti ratio is between about 0.25:1 and 1.65:1.

Claim 25

The process of claim 20 wherein said reaction zone temperature is between about 1350° and 1650° C.

Claim 26

The process of claim 22 wherein Fe/Ti ratio is between about 0.25:1 and 1.65:1.

Claim 27

The process of claim 20 wherein at least about 75% each of said titanium and said iron in said titaniferous material is converted to titanium chlorides and metallic iron, respectively.

Claim 28

The process of claim 24 wherein said conversion is at least about 85%.

Claim 29

The process of claim 25 wherein said conversion is at least about 90%.

Claim 30

The process of claim 20 wherein said chlorinating agent is chlorine gas.

Claim 31

The process of claim 20 wherein said carbonaceous reductant is in finely-divided solid form.

Claim 32

The process of claim 28 wherein the weight concentration of said titaniferous solids and said reductant solids in inlet gases in said mixture is not substantially greater than about 20-kg/m 3 .

Claim 33

The process of claim 29 wherein said concentration is between about 1.6 to 20-kg/m 3 .

Claim 34

The process of claim 20 wherein said iron chlorides are separated from said product stream by quenching said product stream to a temperature sufficient to convert said vaporous iron chlorides into solid state form.

Claim 35

The process of claim 30 wherein said quenching is to a temperature of about 200° to 600° C.

Claim 36

The process of claim 20 wherein said elemental iron is separated from said product stream and TiCl 3 in the remaining product stream is oxidized to TiCl 4 with make-up chlorinating agent.

Claim 37

The process of claim 28 wherein said solid carbonaceous reductant is coke.

Claim 38

The process of claim 34 wherein said coke is made by coking coal.

Claim 39

The process of claim 20 wherein said titaniferous material is prereduced prior to passing it into said reaction zone.

Claim 40

The process of claim 35 wherein said titaniferous material is prereduced simultaneously with said coking.

Claim 41

The process of claim 20 wherein said solid titaniferous material and said solid carbonaceous reductant in admixture are pre-heated to a temperature sufficient to maintain said reaction zone at about 1350° to 1950° C.

Claim 42

The process of claim 16 wherein any unreacted titaniferous material withdrawn from said zone is separated from said product stream and recycled to said zone.

Claim 43

A flow process for essentially completely chlorinating the titanium content of ferruginous titaniferous material whereby essentially all the iron content is converted to metallic form, which comprises: passing through a reaction zone maintained at about 1350° to 1950° C. in substantially laminar flow a mixture of said titaniferous material in finely-divided solid form and having a molar ratio of iron to titanium (Fe/Ti) of about 0.25:1 to 1.65:1; finely-divided solid carbonaceous reductant; a chlorinating agent selected from the group consisting of chlorine gas, HCl, an organo chloride, and mixtures thereof; and iron chlorides recycled from a later step of the process, the molar ratio of said iron chlorides recycled to said titanium (FeCl 2 /Ti) being not substantially above about 1 and the molar ratio of the chlorine in said chlorinating agent to said iron chlorides recycled (Cl 2 /FeCl 2 ) being not substantially less than about 2:1, the atomic ratio of carbon in said mixture to the oxygen content in said mixture being greater than 1:1 for formation of CO, there being no more than about 2 moles of chlorine from said chlorinating agent per gram-atom of titanium in said titaniferous solids, and said Fe/Ti ratio in said titaniferous material and said reaction zone temperature being those whereby the net chlorination of said titanium and reduction of said iron is in a steady-state; withdrawing from said zone a product stream containing titanium chlorides comprising TiCl 4 , by-product metallic iron, carbon monoxide, and iron chlorides comprising ferrous chloride, separating said metallic iron from said product stream; oxidizing any TiCl 3 in said remaining product stream to TiCl 4 with make-up chlorinating agent; separating said iron chlorides from said oxidized product stream by quenching said stream to a temperature of about 200° to 600° C. to convert said iron chlorides to solid state form; recycling said separated iron chlorides to said reaction zone; and withdrawing from said process said separated metallic iron and a vaporous product stream of said crude TiCl 4 and CO.

Claim 44

A flow process for essentially completely chlorinating the titanium content of ferruginous titaniferous material whereby essentially all the iron content is converted to metallic form, which comprises: passing through a reaction zone maintained at about 1350° to 1950° C. in substantially laminar flow a mixture of said titaniferous material in finely-divided solid form and having a molar ratio of iron to titanium (Fe/Ti) of about 0.25:1 to 1.65:1; finely-divided solid carbonaceous reductant; a chlorinating agent selected from the group consisting of chlorine gas, HCl, an organo chloride, and mixtures thereof; and iron chlorides recycled from a later step of the process, the molar ratio of said iron chlorides recycled to said titanium (FeCl 2 /Ti) being not substantially above about 1 and the molar ratio of the chlorine in said chlorinating agent to said iron chlorides recycled (Cl 2 /FeCl 2 ) being not substantially less than about 2:1, the atomic ratio of carbon in said mixture to the oxygen content in said mixture being greater than 1:1 for formation of CO, there being no more than about 2 moles of chlorine from said chlorinating agent per gram-atom of titanium in said titaniferous solids, and said Fe/Ti ratio in said titaniferous material and said reaction zone temperature being those whereby the net chlorination of said titanium and reduction of said iron is in a steady-state; withdrawing from said zone a product stream containing titanium chlorides comprising TiCl 4 , by-product metallic iron, carbon monoxide, and iron chlorides comprising ferrous chloride, separating said metallic iron from said product stream; oxidizing any TiCl 3 in said remaining product stream to TiCl 4 with make-up chlorinating agent; separating said iron chlorides from said oxidized product stream by quenching said stream to a temperature of about 200° to 600° C. to convert said iron chlorides to solid state form; recycling said separated iron chlorides to said reaction zone; and withdrawing from said process said separated metallic iron and a vaporous product stream of said crude TiCl 4 and CO.

Claim 45

The process of claim 40 wherein said chlorinating agent is chlorine gas.

Claim 46

The process of claim 40 wherein the weight concentration of said titaniferous solids and reductant solids in inlet gases in said mixture is not substantially greater than about 20-kg/m 3 .