From Ore to Finished Product: The Titanium Dioxide (TiO₂) Production Process Flow

Titanium dioxide (TiO₂) is a vital industrial pigment used in coatings, plastics, paper, and more. Understanding its production journey—from raw minerals to refined powder—helps manufacturers and buyers make informed decisions. Below, we break down the key stages of TiO₂ manufacturing, comparing the two dominant methods: sulfate and chloride processes.

1. Raw Material Extraction

Source Minerals:

• Ilmenite (FeTiO₃): Primary source for sulfate process (≈90% of global ilmenite use).
• Rutile (TiO₂): High-grade ore preferred for chloride process (purity >95%).

Mining Locations:

• Major ilmenite reserves: Australia, South Africa, China.
• Rutile deposits: Australia, Sierra Leone, Ukraine.

2. Sulfate Process Flow (Dominant in China)

Step 1: Ore Digestion

• Ilmenite is mixed with sulfuric acid (H₂SO₄) to produce titanium sulfate and iron byproducts.

Step 2: Purification

• Iron is removed via crystallization, leaving a titanium-rich solution.

Step 3: Hydrolysis

• Titanium sulfate is hydrolyzed to form hydrated TiO₂.

Step 4: Calcination

• Heating at 800–1000°C produces anatase or rutile TiO₂ powder.

Environmental Note: Generates 20% waste sulfuric acid, requiring recycling systems.

3. Chloride Process Flow (Preferred for High-Grade TiO₂)

Step 1: Chlorination

• Rutile ore reacts with chlorine gas (Cl₂) + coke at 1000°C, forming titanium tetrachloride (TiCl₄).

Step 2: Purification

• TiCl₄ is distilled to remove impurities like vanadium.

Step 3: Oxidation

• TiCl₄ is burned with oxygen at 1500°C to form pure rutile TiO₂ and recycled chlorine.

Advantage: Lower waste, but requires high-purity feedstock.

4. Finishing Steps (Both Processes)

✔ Surface Treatment: Coating particles with silica/alumina to improve dispersibility.
✔ Micronization: Grinding to achieve target particle size (0.2–0.3 μm).
✔ Quality Control: Testing for brightness, opacity, and pH stability.

5. Comparative Overview

6. Industry Trends

• Sustainability: Chloride process gains traction due to EU carbon taxes.
• Innovation: Hybrid methods (e.g., chloride-ilmenite) are being tested to reduce costs.

Did You Know? Producing 1 ton of TiO₂ consumes:

• Sulfate process: 4–6 tons of sulfuric acid
• Chloride process: 1.5 tons of chlorine

Conclusion

The TiO₂ production process significantly impacts product quality, cost, and environmental footprint. Choosing between sulfate and chloride depends on ore availability, end-use requirements, and regulatory compliance.

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• Download our TiO₂ Production Handbook
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