Publication: Preparation of titania from carbosulfidation of Malaysian ilmenite with metal chloride salts
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Date
2025-08-08
Authors
Mohamad Fadzil bin Mohamad Ruslin
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Abstract
The rising global demand for titanium, particularly in the aerospace, medical, and pigment industries, necessitates more efficient and sustainable methods of producing titanium dioxide (TiO₂). Traditional extraction techniques such as the sulfate and chloride processes—are energy-intensive, have low selectivity, and pose environmental issues. This research investigates the production of TiO₂ from Malaysian ilmenite (FeTiO₃) using a novel carbosulfidation method enhanced with metal chloride catalysts, specifically iron (III) chloride (FeCl₃). The process involved mixing ilmenite with graphite and sulfur, adding FeCl₃ as a catalyst and NaCl as a promoter, then conducting carbosulfidation at different temperatures (1000°C–1200°C), reaction times (1 to 3 hours), and catalyst amounts (0–0.0041mol). A 2-level factorial design was employed to optimize these parameters and assess their interaction effects on titanium extraction. Characterization methods, including XRF, XRD, SEM/EDX, and magnetic testing, were used to analyze the phase composition, surface structure, and reduction efficiency. Results showed that the best conditions 1200°C, 3 hours, and 10 wt% FeCl₃ significantly improved the reduction extent (R), reaching 86.23%, and enhanced sulfidization (Xs=10.59 %), indicating an effective reduction of iron from ilmenite. Thermodynamic analysis confirmed favorable Gibbs free energy changes for these reactions especially the formation of FeS2 and TiO2. Morphological evaluations revealed clearer separation of iron-rich and titanium-rich phases, supported by magnetic response tests and SEM/EDX analysis especially in samples 6 with R> 80.61 %. This study demonstrates that FeCl₃ catalyzed carbosulfidation offers
a promising, more efficient alternative for TiO₂ production from ilmenite, with lower carbon use and a smaller environmental footprint. These findingshelp advance sustainable metallurgical processes and position Malaysian ilmenite as a valuable local resource for producing high-purity titanium products.