Weathered Ilmenite: Diverse Mechanisms of Sintering and Association with Contaminants*
Terry C. Parks A , Bob van Emden B C , Nathan A. S. Webster B D , Richard R. Merritt E F , Jim Graham B F and Frank J. Lincoln A GA School of Chemistry and Biochemistry, University of Western Australia, 35 Stirling Highway, Crawley, WA 6009, Australia.
B Research Centre for Advanced Mineral and Materials Processing, University of Western Australia, 35 Stirling Highway, Crawley, WA 6009, Australia.
C Present address: Central Chemical Consulting, 1/11 Narloo Street, Malaga, WA 6009, Australia.
D Present address: CSIRO Process Science and Engineering, Box 312, Clayton South, Vic. 3169, Australia.
E Iluka Resources Ltd (formerly Westralian Sands Pty Ltd), PO Box 96, Capel, WA 6271, Australia.)
F Deceased.
G Corresponding author. Email: frank.lincoln@uwa.edu.au
Australian Journal of Chemistry 65(7) 892-904 https://doi.org/10.1071/CH12032
Submitted: 19 January 2012 Accepted: 22 March 2012 Published: 5 June 2012
Abstract
We briefly review the nature and provenance of extremely weathered ilmenite, then investigate its fate when it is 10 % of a blended feed in the reduction kilns of the Becher process. There it is bound, unintentionally and intermittently, in sinter, which is discarded. It takes with it discrete aluminosilicate grains as well as contaminants, adsorbed and occluded within the ilmenite. Two distinct sintering mechanisms are identified. A layered wall accretion forms purely by solid state reaction, and is thickest early in the kiln. It occasionally detaches under its own weight or is eroded, and is tolerated between scheduled shutdowns for maintenance. However, if the weathered ilmenite and accompanying silica escape earlier wall accretion, a transitory aluminosilicate melt may later promote sintering of this material within the bed, adhering catastrophically to constrictions and obstructions on the kiln wall. The mechanisms and controlling factors are discussed.
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