Titanium Dioxide Project
When Egypt's leading paint manufacturer announced its upstream expansion, investing in a 60,000-ton-per-year titanium dioxide (TiO₂) plant, it wasn't just industry news; it marked the beginning of a grander story about raw material self-sufficiency, technological upgrading, and supply chain integration. As experts with 20 years of experience in mining crushing and grinding, we understand that every successful chemical project begins with the efficient and precise processing of raw materials. This article will delve into the significant challenges and core requirements that such TiO₂ projects place on upstream raw material processing equipment.
Why is raw material pretreatment crucial to success?
Understanding the Starting Point of Titanium Dioxide Production: Ilmenite
You plan to use ilmenite (500 micrometers particle size) as your raw material. Regardless of whether you subsequently use the sulfuric acid process or the chloride process, the pretreatment of the ilmenite is critical. It is not only the first step in production but also one of the decisive factors affecting the purity of the final product, the energy efficiency of the production line, and operating costs.
Raw Material Requirements for Core Processes
◦ Sulfuric Acid Process: Requires grinding ilmenite to a finer particle size (typically -325 mesh, approximately 45 micrometers or less) to increase the reaction contact area and improve the acidolysis rate. The grinding efficiency and particle size distribution directly affect the yield of titanium liquor and the difficulty of subsequent purification.
◦ Chlorination Process: Although it requires higher raw material grade, if ilmenite is used to prepare synthetic rutile or titanium slag, the pretreatment stages such as crushing, grinding, and roasting also require highly reliable and stable equipment support.
Equipment Challenges and Pain Points
1. High Hardness Wear: Ilmenite has a Mohs hardness of 5-6, posing a significant challenge to the wear resistance of equipment.
2. Precise Particle Size Control: A specific fineness range needs to be achieved and stabilized; too coarse or too fine a particle size will affect downstream processes.
3. Continuous and Stable Operation: A production scale of 60,000 tons per year requires the production line to maintain a high operating rate; any unexpected shutdown of critical equipment will result in huge losses.
4. Energy Efficiency and Operating Costs: Crushing and grinding are major energy consumers, and the choice of equipment directly determines production costs for decades to come.
Titanium Dioxide Project: Ilmenite Crushing
Titanium Dioxide Project: Ilmenite Grinding
Titanium Dioxide Project: Ilmenite Crushing and Grinding
Twenty Years of Experience, Building a Reliable Foundation
Based on a deep understanding of mineral characteristics and extensive project experience, we can provide your TiO₂ project with a one-stop, high-performance equipment solution from crushing and grinding to conveying.
• Overview of Core Equipment Advantages
◦ Superior Wear Resistance Technology: The core components of our jaw crushers, cone crushers, and ball mills are made of special alloys or composite materials, designed for high-hardness ferrous minerals. Their lifespan is increased by more than 30% compared to conventional products, significantly reducing maintenance costs and downtime.
◦ Intelligent Particle Size Control: By configuring high-performance hydraulic cone crushers for medium and fine crushing, combined with a closed-circuit grinding system and advanced classification equipment (such as air classifiers), precise and stable control of the output particle size can be achieved, fully meeting the stringent fineness requirements of the sulfate process.
◦ High Reliability Design: The equipment boasts a robust structure, with heavy-duty bearings and transmission systems, combined with an intelligent monitoring system (vibration and temperature sensors) for predictive maintenance, ensuring continuous and stable operation 24/7.
◦ Superior Energy Efficiency: Optimized crushing chamber design and a high-efficiency transmission system ensure lower energy consumption for the same processing capacity, directly helping customers reduce processing costs per ton of raw material.
Success Case Study: Serving a Global Mining Giant
We previously provided a complete crushing and grinding production line for a large ilmenite beneficiation plant in Asia, processing ilmenite ore similar to your project.
• Raw Material: Ilmenite, feed particle size <500mm, target product: -200 mesh 90%.
• Solution: Utilizing a classic and efficient process: jaw crusher + single-cylinder hydraulic cone crusher + multi-cylinder hydraulic cone crusher + ball mill.
• Achievements: The production line has been operating stably for over 5 years, with an average annual equipment uptime exceeding 95%. The comprehensive power consumption per ton of ore is 15% lower than the industry average, and the particle size qualification rate remains consistently above 98%, creating significant economic benefits for the client.
Recommended Equipment for the Project
For the raw material section of your 60,000 tons/year TiO₂ project, we recommend the following core configuration (which can be optimized based on a detailed mineral testing report):
1. Primary Crushing: PE series large jaw crusher for processing large ore blocks.
2. Medium and Fine Crushing: HPT/HST series multi-cylinder hydraulic cone crusher for layered crushing, efficiently producing qualified particle sizes.
3. Ultrafine Grinding: Large ball mill + high-efficiency turbine classifier closed-circuit system for stable and efficient preparation of -325 mesh products.
4. Wear-resistant Conveying System: Equipped with high wear-resistant pipes, valves, and conveying equipment to handle abrasive slurries.
Frequently Asked Questions (FAQ)
Q1: What is the most critical technical challenge in grinding ilmenite with a 500-micron feed to -325 mesh?
A1: The most critical technical challenge lies in balancing high efficiency and wear resistance. Grinding from 500 microns (approximately 35 mesh) to -325 mesh (<45 microns) involves a significant increase in specific surface area, resulting in high energy consumption and severe equipment wear. Our solution employs a process of "multi-stage crushing and precision pre-grinding + high-efficiency fine grinding in a ball mill." First, a cone crusher breaks the material down to the smallest possible particle size (e.g., -5mm) before it enters the ball mill, maximizing energy savings. Simultaneously, the mill lining and grinding media use a special formula to ensure both high-efficiency grinding and an ultra-long service life.
Q2: How does your equipment ensure a stable connection with subsequent chemical production processes (acidolysis or chlorination)?
A2: We ensure stability through a fully automated control system. The system monitors key parameters such as feed rate, equipment load, and product particle size in real time and automatically adjusts them to ensure consistent output quality. A stable raw material supply (composition, particle size) is the cornerstone of stable downstream chemical reactions. We can provide an interface to your DCS system, enabling integrated intelligent control from mining processing to chemical production.
Q3: What kind of technical support and after-sales service can you provide in Egypt?
A3: We have offices and a mature after-sales network in North Africa. Services include:
• Pre-project: Free mineral testing and solution design.
• Installation and commissioning: Dispatching senior engineers to provide on-site guidance for installation and commissioning until production targets are met.
• Local warehousing: Maintaining a stock of commonly used wear-resistant parts in Egypt to ensure rapid supply.
• Long-term support: Providing 24/7 remote technical support, regular equipment health checks, and training for the local operation and maintenance team.
The success of a titanium dioxide project with an investment of hundreds of millions begins with the precise processing of each piece of ore. Choosing the right crushing and grinding partner means laying the foundation for an efficient, stable, and low-consumption plant. We are not just an equipment supplier, but also your trusted process partner, committed to using our 20 years of professional experience to safeguard the first step of your grand vision.
About of Baichy Heavy Industry
Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 、certified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.
Our advantages:
• Professional pre-sales support: Free project design and comprehensive solutions to help you accurately select the right equipment;
• Comprehensive on-site service: Providing installation guidance and worker training to ensure smooth equipment commissioning;
• Reliable after-sales guarantee: A complete after-sales system, timely response to technical inquiries and equipment maintenance, ensuring long-term stable operation.
To protect your rights, please contact us through the following official channels for professional service:
Official Website Customer Service
WhatsApp: 0086-15093222637
Email: [email protected]
We are committed to providing high-quality equipment and full-cycle services to deliver comprehensive intelligent solutions for the global mining industry!
