Refractory lining for titanium ore beneficiation

A process for forming a resistant agent in a refractory body of a furnace for use in a titanium ore beneficiation process, comprising:

• (i) forming agglomerates comprising carbon-based materials and a titanium-bearing ore, the quantity of carbon of the agglomerates being sufficient for, at an elevated temperature, reducing ferric oxide to ferrous oxide and forming a slag that is comprised of titanium oxide and iron oxide;
• (ii) introducing the agglomerates onto a carbon bed of a moving hearth furnace, wherein the moving hearth furnace comprises a refractory lining comprising a first layer comprising alumina and zirconia having about 90 to about 99 wt. % alumina, and about 1 to about 10 wt. % zirconia, based on the entire weight of the first layer;
• (iii) heating the agglomerates in the moving hearth furnace to a temperature sufficient for reducing and melting the agglomerates to produce a titanium oxide-rich molten slag, which contacts the refractory lining to produce a second layer comprising a resistant agent which is a reaction product of the slag, the alumina and the zirconia;
• wherein the second layer is formed between the slag and the first layer;
• and
• wherein the total amount of calcium oxide, magnesium oxide, yttrium oxide and cerium oxide is less than 1 wt. %, based on the total weight of the refractory body.

A preformed layered refractory lining for a furnace, for use in a titanium ore beneficiation process wherein a titanium oxide-rich and iron oxide-rich molten slag is formed, comprising:

• (a) a first layer comprising alumina and zirconia having about 90 to about 99 wt. % alumina, and about 1 to about 10 wt. % zirconia, based on the entire weight of the first layer;
• and
• (b) a paste comprising a source of titania, a source of carbon, and a binder,
• wherein the first layer and the paste are heated prior to beneficiation so that paste forms a second layer attached to the first layer.