Weathered Ilmenite: Diverse Mechanisms of Sintering and Association with Contaminants

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.