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<p>A greener, cleaner, and more efficient process for recovering vanadium from vanadium-titanium magnetite (VTM) concentrate through synergistic roasting with Na<sub>2</sub>CO<sub>3</sub>/CaCO<sub>3</sub> was proposed. This approach aims to enhance the vanadium recovery, reduce the amount of alkaline salts used, and minimize hazardous element levels in tailings. Two alternative process routes, synergistic roasting followed by water or acid leaching, were investigated. The key parameters of the roasting process were modeled and optimized using response surface methodology (RSM) combined with central composite design (CCD). After optimization using the desirability function, the vanadium leaching efficiencies reached 78.47 and 97.72&#xa0;pct via water leaching and acid leaching routes, respectively. This represents an increase in leaching efficiencies by 6.57 and 25.37&#xa0;pct compared to the traditional sodium roasting process. Moreover, the alkali metal Na content in the vanadium extraction tailings can be reduced from 2.3 to 1.65&#xa0;wt pct through water leaching and 0.03&#xa0;wt pct via acid leaching. Similarly, the concentration of the toxic element V can be decreased from 0.24 to 0.18&#xa0;wt pct for water leaching and to 0.02&#xa0;wt pct for acid leaching. The techno-economic analysis indicates that the proposed process leads to a substantial enhancement in overall economic benefits. Additionally, discharging tailings with lower sodium and vanadium contents after processing not only promotes the subsequent comprehensive utilization of iron-enriched tailings but also reduces the risk of environmental pollution.</p> Graphical Abstract <p></p>

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A Greener Approach for Vanadium Extraction from VTM Concentrate via Na2CO3/CaCO3 Synergistic Roasting: Process Optimization, Characterization, and Techno-Economic Evaluation

  • 期刊论文

  • 发表日期：

    2025年5月28日

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  • Luwei Bai,
  • Junyi Xiang,
  • Yaofeng Xu,
  • Shuai Cao,
  • Sheng Liu,
  • Jing Yu,
  • Hongyu Tian,
  • Qingyun Huang,
  • Kuisong Zhu,
  • Xuewei Lv

摘要

A greener, cleaner, and more efficient process for recovering vanadium from vanadium-titanium magnetite (VTM) concentrate through synergistic roasting with Na2CO3/CaCO3 was proposed. This approach aims to enhance the vanadium recovery, reduce the amount of alkaline salts used, and minimize hazardous element levels in tailings. Two alternative process routes, synergistic roasting followed by water or acid leaching, were investigated. The key parameters of the roasting process were modeled and optimized using response surface methodology (RSM) combined with central composite design (CCD). After optimization using the desirability function, the vanadium leaching efficiencies reached 78.47 and 97.72 pct via water leaching and acid leaching routes, respectively. This represents an increase in leaching efficiencies by 6.57 and 25.37 pct compared to the traditional sodium roasting process. Moreover, the alkali metal Na content in the vanadium extraction tailings can be reduced from 2.3 to 1.65 wt pct through water leaching and 0.03 wt pct via acid leaching. Similarly, the concentration of the toxic element V can be decreased from 0.24 to 0.18 wt pct for water leaching and to 0.02 wt pct for acid leaching. The techno-economic analysis indicates that the proposed process leads to a substantial enhancement in overall economic benefits. Additionally, discharging tailings with lower sodium and vanadium contents after processing not only promotes the subsequent comprehensive utilization of iron-enriched tailings but also reduces the risk of environmental pollution.

Graphical Abstract