Titanium Dioxide Production from Ilmenite (Chloride Process)
Titanium Dioxide Production Costs Report | Issue C | Q2 2024
Report Details |
180 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 180 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study comprises a techno-economic analysis of an industrial process for Titanium Dioxide production from ilmenite in a facility located in the United States. In this process, ilmenite is converted by Benelite process into synthetic rutile, which is then chlorinated to titanium tetrachloride, and further oxidized to Titanium Dioxide.
The report provides a comprehensive study of Titanium Dioxide production and related Titanium Dioxide production cost, covering three key aspects: a complete description of the Titanium Dioxide production process examined; an in-depth analysis of the related Titanium Dioxide plant capital cost (Capex); and an evaluation of the respective Titanium Dioxide plant operating costs (Opex).
The Titanium Dioxide production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Titanium Dioxide plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Titanium Dioxide plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises four major sections: (1) Ilmenite Beneficiation; (2) Chlorination; (3) TiCl4 Oxidation; and (4) Finishing and Packing.
Ilmenite Beneficiation. Ilmenite is first reduced in a rotary kiln to convert iron (III) ions to iron (II). Next, the mineral is leached with hydrochloric acid (HCl), which dissolves the iron, leaving behind a solid material rich in titanium dioxide (TiO?). After a calcination step, synthetic rutile is obtained. The iron chloride generated during the leaching process undergoes pyrohydrolysis, which breaks the chloride and generates HCl, and Fe2O3. The HCl is absorberd and recycled as leaching acid whille the iron oxide is discarded.
Chlorination. Synthetic rutile, coke, and chlorine gas are fed to the Chlorination reactor, yielding titanium tetrachloride (TiCl4) and carbon dioxide as main products. The gases from the reactor are sent to a cooling condensing column and quenched with a condensed liquid stream of impure TiCl4. Further in condensation, a TiCl4 stream is contacted with cold liquid, and most of the TiCl4 condenses and is sent to Purification, where the remaining impurities are removed and the non-condensable gases are routed to the Caustic Scrubber, which generates an off-gas stream that is used as fuel in the plant.
TiCl4 Oxidation. A purified TiCl4 stream from Purification is mixed with an aluminum chloride stream and fed to the Oxidation Reactor. Hot oxygen is also fed to this reactor, reacting with TiCl4 and generating Titanium Dioxide (TiO2). The gaseous suspension of TiO2 particles from the reactor is directed to be cooled and passed through a cyclone to separate TiO2 powder from the gas stream, which is sent to Cl2 Recovery, a liquefaction unit that recovers Cl2 for Chlorination.
Finishing and Packing. The TiO2 particles obtained in the cyclone are ground and reduced, being then coated with silica/boria layers, and washed on a filter for residual salt removal. After the washing, the particles are dried by a heated air stream in a dryer, routed to a micronizer for grinding, and finally packed in bags before being sent to storage.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Titanium Dioxide production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Titanium Dioxide process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Titanium Dioxide production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Titanium Dioxide plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Titanium Dioxide Production Cost Reports
Titanium Dioxide Production from Synthetic Rutile (Chloride Process)
This study comprises a techno-economic analysis of an industrial process for Titanium Dioxide production from rutile in a United States-based facility. In this process, rutile is chlorinated to titanium tetrachloride, which is then oxidized to Titanium Dioxide.
Details: 150 kta United States-based plant | Q2 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 150 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Titanium Dioxide Production from Ilmenite (Sulfate Process)
This report presents a feasibility study of Titanium Dioxide production from ilmenite in United States. In this process, ilmenite is digested with sulfuric acid forming titanyl sulfate, which is hydrolyzed to hydrated titanium dioxide. Then, it is calcinated to titanium dioxide.
Details: 120 kta United States-based plant | Q2 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 120 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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