Factors affecting the leaching mechanism of Mg bearing oxide impurities in Hydrogen Assisted Magnesiothermic Reduction (HAMR) of TiO2

Titanium production by a direct TiO₂ reduction route which is highly energy-efficient and environment-friendly compared to commercial Kroll's process, known as HAMR (Hydrogen Assisted Magnesiothermic Reduction) process has been developed in recent times to meet the growing global demands of low-cost pure Ti. Removal of the Mg compounds after each reduction and de-oxygenation step in the HAMR process by leaching, is essential to ensure good purity and mechanical properties of the final Ti powder. In this study, we investigate the effects of temperature, particle size, and pH on the dissolution kinetics of Mg from Mg-bearing compounds such as MgO and MgCl₂ that remain after the HAMR Process. We also report the underlying mechanism and rate-controlling steps of Mg removal using HCl in connection with the HAMR process. The dissolution kinetics followed a logarithmic rate kinetic model for diffusion through a porous medium that is commonly used for battery research. Kinetics of leaching were significantly improved using finer particles with 99.96 wt.% Mg removal and corresponding Ti loss of only 1.8 wt. %. The rate of dissolution exhibited a weak dependence with the pH and did not abide by the rate-controlling steps of dissolution of ionic oxides like MgO proposed by previous kinetic models.