Titanium Dioxide Production from Ilmenite (Sulfate Process)
Titanium Dioxide Production Costs Report | Issue B | Q4 2024
| Report Details |
| 120 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 120 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 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.
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 three major sections: (1) Ilmenite Processing; (2) Titanium Dioxide Hydration; and (3) Titanium Dioxide Treatment.
Ilmenite Processing. Initially, ilmenite (FeTiO3) ores are dried to a moisture content of
Titanium Dioxide Hydration. The solution, at this point rich in titanyl sulfate, TiOSO4, is then submitted to a hydrolysis reaction where the titanyl sulfate is converted to insoluble, hydrated titanium dioxide. The hydrolysis effluent is passed through vacuum filters, in such a way that the titanium oxide hydrate is separated from the solution and washed with water. The acid solution is concentrated in multiple columns and recycled in order to be reused in the digestion.
Titanium Dioxide Treatment. The hydrated Titanium Dioxide is heated in a rotary kiln, what causes water evaporation and decomposition of residual sulfuric acid in the solid. The weak acid from the calcination and sludge from titanyl sulfate purification are neutralized with lime. After a filtration, the resulting sludge is discharged while the filtrate is recycled to the first section. The Titanium Dioxide crystals obtained are milled to a specific size, coated, dried and finally packed.
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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
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