Direct smelting process
A molten bath-based direct smelting process comprises controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise when the slag temperature is in the range of 1400-1550° C. in the molten bath in the vessel.
1. A slag product of a direct smelting process, the slag product comprising molten slag that includes:
TiO 2 : at least 15 wt. %,
SiO 2 : at least 15 to 20 wt. %,
CaO: at least 15 to 30 wt. %,
Al 2 O 3 : at least 10 to 20 wt. %,
FeO: at least 3 to 10 wt. %,
carbon content: 3-5 wt. %, and
vanadium oxide comprising more than 50% of a total vanadium output from the direct smelting process.
2. The slag product defined in claim 1 , wherein vanadium in the slag product comprises more than 65% of the total vanadium output from the direct smelting process.
3. The slag product defined in claim 1 , wherein vanadium in the slag product comprises more than 80% of the total vanadium output from the direct smelting process.
4. The slag product defined in claim 1 , wherein the molten slag comprises at least 20 wt. % TiO 2 .
5. The slag product defined in claim 1 , wherein the molten slag comprises at least 50 wt. % TiO 2 .
6. The slag product defined in claim 1 , wherein the molten slag further comprises manganese oxide.
7. A feed material for a sulphate process for producing pigment-grade titania, the feed material being a product of a directing smelting process and having a microstructure that is amenable to processing in the sulphate process and wherein the feed material comprises:
TiO 2 : at least 15 wt. %,
SiO 2 : at least 15 to 20 wt. %,
CaO: at least 15 to 30 wt. %,
Al 2 O 3 : at least 10 to 20 wt. %,
FeO: at least 3 to 10 wt. %,
carbon content: 3-5 wt %, and
vanadium oxide comprising more than 50% of a total vanadium output from the direct smelting process.
8. The feed material defined in claim 7 , wherein vanadium in the vanadium oxide comprises more than 65% of the total vanadium output from the direct smelting process.
9. The feed material defined in claim 7 , wherein vanadium in the vanadium oxide comprises more than 80% of the total vanadium output from the direct smelting process.
10. The feed material defined in claim 7 , wherein the feed material comprises at least 20 wt. % TiO 2 .
11. The feed material defined in claim 7 , wherein the feed material comprises at least 50 wt. % TiO 2 .
12. The feed material defined in claim 7 , wherein the feed material further comprises manganese oxide.