FEEDSTOCK COMPOSITE WITH CARBONACEOUS MATERIAL HAVING A TAILORED DENSITY

Abstract

The invention relates to a feedstock composite comprising a metal oxide fraction and a carbonaceous fraction, a binder composition and the use thereof for obtaining the feedstock composite. Further, the invention refers to a method for obtaining the feedstock composite.

Claims

1. A feedstock composite comprising a metal oxide fraction and a carbonaceous fraction, wherein the carbonaceous fraction has a carbonaceous fraction poured bulk density of not more than about 0.8 g/cm.sup.3 and a particle density of from about 0.85 g/cm.sup.3 to about 1.15 g/cm.sup.3.

2. The feedstock composite of claim 1, wherein the carbonaceous fraction poured bulk density is not more than about 0.7 g/cm.sup.3.

3. The feedstock composite of claim 2, wherein the carbonaceous fraction poured bulk density is not more than about 0.6 g/cm.sup.3.

4. The feedstock composite of claim 1, wherein the feedstock composite possesses a feedstock composite poured bulk density of from about 0.7 g/cm.sup.3 to about 2.0 g/cm.sup.3.

5. The feedstock composite of claim 4, wherein the feedstock composite poured bulk density is from about 0.9 g/cm.sup.3 to about 1.7 g/cm.sup.3.

6. The feedstock composite of claim 5, wherein the feedstock composite poured bulk density is from about 1.2 g/cm.sup.3 to about 1.5 g/cm.sup.3.

7. The feedstock composite of claim 1, wherein the carbonaceous fraction is selected from the group consisting of fine petroleum coke, recycled petroleum coke, bio char, char coal, pyrolyzed brown coal, pyrolyzed peat, pyrolyzed coke, and mixtures thereof.

8. The feedstock composite of claim 1, wherein the feedstock composite possesses the form of particles having a size of from about 0.1 mm to about 6.0 mm.

9. The feedstock composite of claim 1, wherein the feedstock composite possesses the form of particles having a size of from about 0.3 mm to about 4.0 mm.

10. The feedstock composite of claim 1, wherein the feedstock composite possesses the form of particles having a size of from about 0.5 mm to about 3.0 mm.

11. The feedstock composite of claim 1, wherein the metal oxide fraction is a titaniferous fraction, and that the titaniferous fraction is selected from the group consisting of natural rutile, synthetic rutile, titaniferous slag, recycled titaniferous slags, residual slags, ilmenite, and mixtures thereof.

12. The feedstock composite of claim 1, further comprising at least one binder selected from the group consisting of sodium chloride, sodium carbonate, bentonite, water glass, carbon black, soth, polyvinyl alcohol, plasticizers, lignosulfonate, carboxymethylcellulose, starch, starch ether, tars, bituminous, molasse, natural resin, pitch, gelatin, tannin, and mixtures thereof.

13. The feedstock composite of claim 12, wherein the at least one binder comprises lignosulfonate, carboxymethylcellulose, water glass and bentonite in a ratio of lignosulfonate, carboxymethylcellulose, water glass and bentonite from about 1:2:2:2 to about 1:3:4:4.

14. The feedstock composite of claim 12, wherein the at least one binder is from about 1 wt. % to about 20 wt. %, with respect to the total weight of the feedstock composite.

15. The feedstock composite of claim 14, wherein the at least one binder is from about 3 wt. % to about 17.5 wt. %, with respect to the total weight of the feedstock composite.

16. The feedstock composite of claim 12, wherein the at least one binder is from about 7.5 wt. % to about 13 wt. %, with respect to the total weight of the feedstock composite.

17. The feedstock composite of claim 1, wherein: the carbonaceous fraction poured bulk density is not more than about 0.6 g/cm.sup.3; the feedstock composite has a feedstock composite poured bulk density from about 1.2 g/cm.sup.3 to about 1.5 g/cm.sup.3; the carbonaceous fraction is selected from the group consisting of fine petroleum coke, recycled petroleum coke, bio char, char coal, pyrolyzed brown coal, pyrolyzed peat, pyrolyzed coke, and mixtures thereof; the feedstock composite possesses the form of particles having a size of from about 0.5 mm to about 3.0 mm; the metal oxide fraction is a titaniferous fraction, and that the titaniferous fraction is selected from the group consisting of natural rutile, synthetic rutile, titaniferous slag, recycled titaniferous slags, residual slags, ilmenite, and mixtures thereof; the feedstock composite further comprises at least one binder comprising lignosulfonate, carboxymethylcellulose, water glass and bentonite in a ratio of lignosulfonate, carboxymethylcellulose, water glass and bentonite from about 1:2:2:2 to about 1:3:4:4; and wherein the at least one binder is from about 7.5 wt. % to about 13 wt. %, with respect to the total weight of the feedstock composite.

18. A method for producing the feedstock composite of claim 1, comprising: a) combining a metal oxide material and a carbonaceous material to form a raw mixture, wherein the carbonaceous material possesses a poured bulk density of not more than about 0.8 g/cm.sup.3; and b) agglomerating the raw mixture to obtain the feedstock composite.

19. The method of claim 18, wherein the metal oxide fraction is a titaniferous fraction selected from the group consisting of natural rutile, synthetic rutile, titaniferous slag, recycled titaniferous slags, residual slags, ilmenite, and mixtures thereof.

20. The method of claim 18, further comprising combining at least one binder into the raw mixture prior to step b), wherein the at least one binder is selected from the group consisting of sodium chloride, sodium carbonate, bentonite, water glass, carbon black, soth, polyvinyl alcohol, plasticizers, lignosulfonate, carboxymethylcellulose, starch, starch ether, tars, bituminous, molasse, natural resin, pitch, gelatin, tannin, and mixtures thereof.

21. The method of claim 20, wherein the binder composition comprises lignosulfonate, carboxymethylcellulose, water glass, and bentonite, in a ratio of from about 1:2:2:2 to about 1:3:4:4.

22. The method of claim 17, wherein agglomeration in step b) is accomplished by a method selected from the group consisting of compacting, extrusion, wet extrusion, pressure agglomeration, dry agglomeration, tumble growth agglomeration, heating, sintering, and combinations thereof.

23. The method of claim 17, further comprising after step a) and prior to step b): confecting the raw mixture by a method selected from the group consisting of drying, wetting, pre-agglomeration, and combinations thereof.

Description

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] These and other aspects, features and advantages of the invention become obvious to the skilled person from the study of the following detailed description and claims. Each feature from one aspect of the invention can be employed in any other aspect of the invention. Numerical ranges stated in the format from x to y include the mentioned values and the values that are within the respective measuring accuracy as known to the skilled person. If several preferred numerical ranges are stated in this format, it is a matter of course that all ranges formed by the combination of the various end points are also included. The use of the term about is intended to encompass all values that lie within the range of the respective measurement accuracy known to the skilled person.

[0017] In a first aspect, the invention relates to a feedstock composite comprising a metal oxide fraction and a carbonaceous fraction, wherein the carbonaceous fraction has a poured bulk density of about 0.8 g/cm.sup.3 or less, preferably about 0.7 g/cm.sup.3 or less, and more preferably about 0.6 g/cm.sup.3 or less, and a particle density of from about 0.85 g/cm.sup.3 to about 1.15 g/cm.sup.3. The poured bulk density of the carbonaceous fraction is preferably not less than preferably about 0.3 g/cm.sup.3 or less, and more preferably about 0.2 g/cm.sup.3. The feedstock possess preferably a poured bulk density of from about 0.7 g/cm.sup.3 to about 2.0 g/cm.sup.3, more preferably of from about 0.9 g/cm.sup.3 to about 1.7 g/cm.sup.3, and more even preferably of from about 1.2 g/cm.sup.3 to about 1.5 g/cm.sup.3. In a preferred embodiment, the feedstock composite possesses a poured bulk density of from about 0.7 g/cm.sup.3 to about 2.0 g/cm.sup.3, preferably of from about 0.9 g/cm.sup.3 to about 1.7 g/cm.sup.3, and more preferably of from about 1.2 g/cm.sup.3 to about 1.5 g/cm.sup.3. In yet another preferred embodiment, the feedstock composite possesses the form of a particle, and preferably the particle has a size of from about 0.1 mm to about 6.0 mm, preferably of from about 0.3 mm to about 4.0 mm, and more preferably of from about 0.5 mm to about 3.0 mm rendering the composite highly suitable for carbochlorination processes.

[0018] Poured bulk density, as used herein relates to the mass per volume of the composite feedstock and a continuous fluid filling the voids between the composite feedstock, wherein the fluid is air and the individual components of the feedstock material must not dissolve into each other. The procedure described in DIN 53468 was used to determine the poured bulk density. Particle density, as used herein relates to the mass per volume of a solid. The procedure described in ISO 12154 was used to determine the poured bulk density.

[0019] The carbonaceous fraction is preferably selected from the group consisting of fine petroleum coke, recycled petroleum coke, bio char, char coal, pyrolyzed brown coal, pyrolyzed peat, and pyrolyzed coke can be used. Further, substances such as cokes generated from organic recycled materials or secondary or tertiary raw materials by e.g. pyrolysis and similar processes that generate coke, hydrothermally generated coke (HTC) from sewage sludge, manure, wood, straw or other agricultural residues, appropriate fractions of municipal waste. Fine petroleum coke, as used herein refers to a petroleum coke with a poured bulk density of about 0.5 g/cm.sup.3 or less, preferably about 0.4 g/cm.sup.3 or less.

[0020] The metal oxide fraction can be any metal oxide used as starting material of carbochlorination process comprised of any metal of interest such refractory metals, among them, niobium, tantalum, tungsten, molybdenum and rhenium, rare earth metals like cerium, neodymium, samarium or light metals such as aluminum, silicon, vanadium or titanium or other metals like zirconium. Preferably, the ores and slags containing the above can be used. Preferably, the metal oxide fraction is a titaniferous fraction, and that the titaniferous fraction is selected from the group consisting of natural rutile, synthetic rutile, titaniferous slag, recycled titaniferous slags, residual slags, and ilmenite. The residual slag can originate from the iron and steel industry.

[0021] In order to improve the adhesion of the fraction of the feedstock composite, at least one binder can be used selected from the group consisting of sodium chloride, sodium carbonate, bentonite, water glass, carbon black, soth, polyvinyl alcohol, plasticizers, lignosulfonate, carboxymethylcellulose, starch, starch ether, tars, bituminous, molasse, natural resin, pitch, gelatin, and tannin Starch ether can be obtained from Agrana Beteilungs-AG in Vienna, Austria. Preferably, a binder composition comprising lignosulfonate, carboxymethylcellulose, water glass and bentonite, preferably the ratio of lignosulfonate, carboxymethylcellulose, water glass and bentonite is from about 1:2:2:2 to about 1:3:4:4 is employed which is advantageous in carbochlorination processes. Preferably, the feedstock composite further comprises from about 1 wt. % to about 20 wt. %, preferably from about 3 wt. % to about 17.5 wt. %, and more preferably from about 7.5 wt. % to about 13 wt. % of the at least one binder or the binder composition with respect to the total weight of the feedstock composite.

[0022] In another aspect, the invention relates to a binder composition comprising lignosulfonate, carboxymethylcellulose, water glass, and bentonite. Preferably, the ratio of lignosulfonate, carboxymethylcellulose, water glass, and bentonite is of from about 1:2:2:2 to about 1:3:4:4 is used.

[0023] In yet another aspect, the invention is directed to the of the binder composition as disclosed herein for obtaining a feedstock composite comprising a metal oxide fraction and a carbonaceous fraction, preferably for obtaining a feedstock composite as described herein. Even more preferably, the binder composition according to the invention is employed for obtaining a feedstock composition for the titanium dioxide chloride process.

[0024] In a further aspect, the invention related to a method for obtaining the feedstock composite comprising a metal oxide fraction and a carbonaceous fraction, comprising the steps of [0025] a) providing a raw mixture of a metal oxide material and a carbonaceous material, wherein the carbonaceous material possesses a poured bulk density of about 0.8 g/cm.sup.3 or less, preferably about 0.7 g/cm.sup.3 or less, and more preferably about 0.6 g/cm.sup.3 or less, and [0026] b) agglomerating the raw mixture to obtain the feedstock composite.

[0027] The agglomeration in step b) can be accomplished by compacting and/or extrusion and/or wet extrusion, preferably extrusion. Further, pressure agglomeration, dry agglomeration, tumble growth agglomeration, heating or sintering can also be used.

[0028] Preferable, step after step a) and prior to step b), the raw mixture is confected by drying, wetting and/or pre-agglomeration. This step is conducted to prepare the raw mixture for the step b). Apparatuses and techniques are known in the art, for example, a disc pelletizer. The particle size of the feedstock can also be adjusted by common reduction techniques.

[0029] The metal oxide fraction can be any metal oxide used as starting material of carbochlorination process comprised of any metal of interest such as refractory metals, among them, niobium, tantalum, tungsten, molybdenum and rhenium, rare earth metals like cerium, neodymium, samarium or light metals such as aluminum, silicon, vanadium or titanium or other metals like zirconium. Preferably, ores and slags containing the above can be used. Preferably, the metal oxide fraction is a titaniferous fraction, and that the titaniferous fraction is selected from the group consisting of natural rutile, synthetic rutile, titaniferous slag, recycled titaniferous slags, residual slags, and ilmenite. The residual slag can originate from the iron and steel industry.

[0030] In order to improve the adhesion of the fraction of the feedstock composite, at least one binder can be added in step a) selected from the group consisting of sodium chloride, sodium carbonate, bentonite, water glass, carbon black, soth, polyvinyl alcohol, plasticizers, lignosulfonate, carboxymethylcellulose, starch, starch ether, tars, bituminous, molasse, natural resin, pitch, gelatin, and tannin Starch ether can be obtained from Agrana Beteilungs-AG in Vienna, Austria. Preferably, a binder composition comprising lignosulfonate, carboxymethylcellulose, water glass and bentonite, preferably a ratio of lignosulfonate, carboxymethylcellulose, water glass and bentonite from about 1:2:2:2 to about 1:3:4:4 is employed which is advantageous in carbochlorination processes. Preferably, the feedstock composite further comprises from about 1 wt. % to about 20 wt. %, preferably from about 3 wt. % to about 17.5 wt. %, and more preferably from about 7.5 wt. % to about 13 wt. % of the at least one binder or the binder composition with respect to the total weight of the feedstock composite.

[0031] The above descriptions of certain embodiments are made for the purpose of illustration only and are not intended to be limiting in any manner Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading the present disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled.