Synthetic rutile is produced all over the world by processing ilmenite through conventional chloride and sulphate routes. In both of these processes, considerable amounts of iron chloride/sulphate and spent acids are produced as by-products which are environmental pollutants. Metallic iron is produced as a by-product of carbothermic smelting of ilmenite and enriching titania content of slag to 75 to 85%. Processing of titania rich slag reduces the generation of pollutants considerably. In this paper, an alternate method of preparing titania rich slag by in-flight thermal plasma processing of prereduced ilmenite is presented. It has been possible to prepare 76% TiO2-containing slag with an energy consumption of 1.2 kWh/kg at a feed rate of 16.5 kg/h.
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