Commodity Production Costs Report

Titanium Dioxide Production from Ilmenite (Chloride Process)

Titanium Dioxide Operating Costs & Plant Construction Costs

180 kta United States-based plant | 107 Pages | Issue C | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

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.

Key reference(s): ?

Titanium Dioxide Production Cost Report 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 (TiO2). 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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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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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
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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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

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