Recovery of TiO2 from ilmenite-type ore by a membrane based electrodialysis process

Claim 2

In a process for producing titanium dioxide from ilmenite-type ore including the steps of (a) digesting ilmenite ore with aqueous hydrogen fluoride to form a solution of titanium fluoride compounds and soluble iron fluoride impurities; (b) adding aqueous ammonium fluoride and ammonium hydroxide to substantially precipitate iron-ammonium fluoride impurities from the solution; (c) separating the remainder of the iron fluoride impurities by precipitating with ammonium sulfide and filtering off; (d) adding ammonium hydroxide to precipitate hydrated titanium dioxide and to form aqueous ammonium fluoride; (e) calcining the hydrated titanium dioxide to form pigmentary titanium dioxide; and (f) converting the precipitated iron-ammonium fluoride impurities from step (b) to form iron oxide and aqueous ammonium fluoride, the improvement which comprises subjecting the combined ammonium fluoride solutions from steps (d) and (f) to electrodialytic water-splitting to form an aqueous solution of ammonium hydroxide and an aqueous solution of hydrogen fluoride and recycling said aqueous ammonium hydroxide to step (d), and said aqueous hydrogen fluoride to step (a).

Claim 3

The improvement in accordance with claim 1 wherein the combined solution of ammonium fluoride is subjected to electrodialytic water-splitting by introducing the solution into a salt compartment of a unit cell in an electrodialytic water-splitting assembly sequentially comprising: anode compartment; at least one unit cell; cathode, said anode compartment containing an anode immersed in an anolyte and said cathode compartment containing a cathode immersed in a catholyte, the unit cell sequentially comprising: anion-permeable membrane; salt compartment; cation-permeable membrane; base compartment; bipolar membrane; acid compartment; wherein the acid compartment contains dilute hydrofluoric acid and the base compartment contains dilute ammonium hydroxide, in which assembly under the influence of an applied current, ammonium ion is caused to migrate from the salt compartment through the cation-permeable membrane into the base compartment and is constrained from migrating out of the base compartment by the bipolar membrane, and hydroxyl ion is caused to migrate from the bipolar membrane into the base compartment forming ammonium hydroxide, and fluoride ion is caused to migrate into the acid compartment through the anionpermeable membrane from an adjacent salt compartment and is constrained from migrating out of the acid compartment by the bipolar membrane, and hydrogen ion is caused to migrate from the bipolar membrane into the acid compartment, thus forming hydrofluoric acid, wherein the current in the assembly is transported by migrating cations and anions, and the aqueous ammonium hydroxide in the base compartment is drawn off and recycled to step (d) and the aqueous hydrofluoric acid is drawn off and recycled to step (a).

Claim 4

The improvement in accordance with claim 1 wherein the combined solution of ammonium fluoride is subjected to electrodialytic water-splitting by introducing the solution into the base compartment of a bipolar membrane cell in an electrodialytic water-splitting assembly sequentially comprising: anode compartment; at least one bipolar membrane cell; cathode compartment, said anode compartment containing an anode immersed in an anolyte and said cathode compartment containing a cathode immersed in a catholyte, said bipolar membrane cell sequentially comprising anion-permeable membrane; base compartment; bipolar membrane; acid compartment; wherein the acid compartment contains dilute hydrofluoric acid, in which assembly under the influence of an applied electric potential, fluoride ion is caused to migrate out of the base compartment through the anion-permeable membrane into an adjacent acid compartment and is constrained from migrating out of the acid compartment by the bipolar membrane, and hydrogen ion is caused to migrate from the bipolar membrane into the acid compartment thus forming hydrofluoric acid, and hydroxyl ion is caused to migrate from the bipolar membrane into the base compartment, thus forming ammonium hydroxide, wherein the current in the assembly is transported by migrating cations and anions, and said aqueous ammonium hydr xide is drawn off from the base compartment and recycled to step (d) and said hydrofluoric acid is drawn off and recycled to step (a).

Claim 5

The improvement in accordance with claim 1 wherein the aqueous ammonium hydroxide solution produced by electrodialytic water-splitting contains ammonium fluoride.

Claim 6

The improvement in accordance with claim 1 wherein the aqueous hydrofluoric acid solution produced by electrodialytic water-splitting contains ammonium fluoride.