Extractive Metallurgy Of Vanadium Containing Titaniferous Magnetite Ores: A Review

Introduction In modern society, vanadium is defined as a strategic metal. Some 90% of the global consumption is used as an alloying agent for carbon steels, tool steels, and high-strength low-alloy steels (particularly for pipelines). Advanced titanium-aluminum-vanadium alloys are seeing application in the aerospace industry. Small but ever growing amounts are finding application as catalysts or in electronics. New uses are continually being discovered for this metal. One example of a new application is the vanadium-redox battery for use in generation plants and back-up power sources. Vanadium is found in a large number of minerals, of which the most important are carnotite, roscoelite, vanadinite, mottramite, and patronite. Just over a third of the world's vanadium is produced as a primary product; the balance is a by-product of the iron and steel, oil refining, power generation and uranium enrichment industries. Vanadium can also be sourced by recycling spent catalysts from the petrochemical industry and ash produced by the combustion of oil emulsion in power stations. However, recycling activities are believed to account for only a small amount of total world supply. Vanadium is recovered from these ores largely as the pentoxide (V2O5) [1]. The major sources of vanadium-bearing magnetite ores are scattered throughout Australia, China, Russia, and South Africa. Current estimates of world’s Proven & Probable vanadium reserves are of the order of 41.3 million tones [2, 3]. Commercial vanadium-bearing titaniferous magnetite deposits can be found in Kachkanar, Russia; Pan Zhihua, China; Bushveld, South Africa; and Windimurra, Western Australia [4]. Other deposits have been found in New Zealand, Canada, and India, among other countries. Vanadium consumption in the steel sector has increased some 7% per ton of steel over the last 10 years as new alloying applications have been found to improve steel's strength-to-weight ratio. Future demand from the aerospace and nuclear industries for non-ferrous vanadium alloys such as titanium and super-alloys is also likely to grow. Vanadium is usually added in the form of ferrovanadium, a vanadium-iron alloy. Vanadium compounds, especially the pentoxide form, are used in the ceramics, glass, and dye industries, and are also important as catalysts in the chemical industry. While established approaches may be used at an industrial scale to treat vanadium-bearing titaniferous magnetite ores in several countries, new alternatives are being developed worldwide. This review will give short overview of the treatment of vanadium-bearing titaniferous magnetite ores, an overview of direct reduction and direct smelting processes and an approach to determine technical alternatives for the property.