Process for the preparation of high grade synthetic rutile and pig iron

An improved process for the preparation of high grade synthetic rutile from ilmenite with pig iron as a by-product, said process comprising, subjecting ilmenite to reduction with 30-100% coal (w/w) at a temperature in the range of 850-1250° C. for a period of 2-6 hours thereby producing ash, cooling and removing unreacted coal to obtain a product having 80-95% metallisation;

• smelting the metallised ilmenite mixed with less than 10% carbon (w/w) in a transferred arc plasma using arc current in the range of 100-400 amps., arc voltage of 20-60 V under flow of inert gas at a range of 0-2 liters/minute for a fixed time in the range 1-5 minutes;
• separating the metal as pig iron and TiO2 as slag;
• grinding the slag followed by oxidation in a temperature range of 500-1000° C. in the presence of an oxidizing gas for 25-30 minutes, followed by leaching the oxidised product with dilute HCl at temperatures below 90° C. for a period of 1-6 hours followed by filtration, washing and drying to obtain synthetic rutile.