A Novel Approach for the Comprehensive Utilization of High Carbon Vanadium-Bearing Shale

High carbon vanadium-bearing shale is an ore with large reserves, characterized by abundant silica, carbon, and sulfur, but low vanadium grade. However, conventional methods of utilizing high carbon vanadium-bearing shales focus only on vanadium extraction, neglecting the recovery of other associated elements. In this study, a novel approach was proposed for the separation of vanadium, preparation of SiC, and recovery sulfur simultaneously. Fe powder was selected as additive to mix with high carbon vanadium-bearing shale. Then, through reduction roasting, vanadium was dissolved into magnetic Fe₃Si phase; SiC was prepared by the reaction of C and SiO₂; sulfur volatilized from the decomposition of sulfur-containing minerals. Finally, vanadium- containing Fe₃Si phase and SiC were separated via the magnetic method, while sulfur was recovered from volatiles. The results showed that the sample with 5 wt.% Fe powder addition roasted at 1400 °C for 10 h demonstrated a 3.62 wt.% vanadium in Fe₃Si phase with 80.16% vanadium recovery rate, a 96.3% conversion ratio of SiC, and a 95.5% sulfur recovery rate. Furthermore, it was found that Fe powder not only separated vanadium, but also played an important catalytic effect on the preparation of SiC. This novel approach not only effectively separated vanadium, but also prepared SiC and recovered sulfur, and greatly reduced waste generation.