Andriy Gonchar,
Director of RD Titan Group Innovative TiO2
Report Summary
Historical background and comparison of sulfate and chloride technologies for the production of titanium dioxide.
New environmental requirements imposed recently in different countries of the world and their impact on further development of titanium dioxide technologies.
Updated sulfate titanium dioxide production technology by RD Titan Group Innovative TiO2:
• Environmental safety: radical reduction in solid waste generation, no liquid effluents (Zero Liquid Discharge (ZLD) principle), significantly reduced carbon footprint, and compliance with the most stringent emission requirements.
• Combined solutions to achieve the new level of energy efficiency: reduced gas/ power/ steam consumption, recycling of sewage water, possibility of using artesian water with high salt content for areas with freshwater deficit, on-site power generation to cover up to 100% of power demand.
• A ‘smart factory’ concept: automation and production management inspired by Industry 4.0 trends.
• Focus on a wide range of high value-added products:
o maximum variety of titanium dioxide grades to capture the maximum number of application niches;
o production of high value-added by-products with high market demand, which provides up to 50% of sales revenue.
• New economic level:
o significant reduction in the cost of production;
o EBITDA increase by 1.5 to 3.0 times compared to the production plants currently using sulfate and chloride technology;
o short payback period of investments (2.5 to 3.5 years since the start of production).
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Updated TiO2 Sulfate Technology: New Perspectives on Environmental Safety, Energy and Economic Efficiency, and High Value-Added Products
1. Updated
TiO2 Sulfate Technology
by RD Titan Group Innovative TiO2
All titanium dioxide technologies in one place
New perspectives in the context of environmental safety,
energy and economic efficiency and high value added
products
2. All titanium dioxide technologies in one place
Disclaimer.
The source of the technologies, know-how, knowledge, experience, etc. for this presentation is the company RD Titan Group Innovative TiO2, TOV (Ukraine) with the participation of
their associated partner Appleton International Limited (United Kingdom). The employees of RD Titan Group Innovative TiO2 and those of their partner have extensive experience
in titanium dioxide plant design and operations (with such companies as Laporte, SCM, Millennium, Tioxide, Crimea Titan, Cristal, Tronox).
The proprietary technology AITiO2ST™ mentioned in this presentation is the most advanced sulfate technology developed by RD Titan Group Innovative TiO2 to achieve the
highest performance.
Every effort has been made to ensure that the information presented and the conclusions reached are realistic and not misleading. However RD Titan Group Innovative TiO2 make
no warranty as to the accuracy of the information contained in this presentation and will not accept responsibility or liability for any loss incurred by any person or organization
relying on the information in this presentation.
www.innovativetio2.com
Andriy Gonchar
Director of
RD Titan Group Innovative TiO2
3. Stages of TiO2 Production Technologies
Development
3
1916
Launch of anatase
production (sulfate
route)
1939
Launch of
rutile
production
(sulfate route)
1948
Launch of
rutile
production
(chloride
route)
1960-
2000
Evolution of
sulfate and
chloride
technologies
2000-
2010
Explosive
growth in
the number
of sulfate
plants in
China
2010-
2019
Launch of
new chloride
plants in
China
All titanium dioxide technologies in one place
4. Sulfate vs Chloride: Comparison of Technologies
Parameters Sulfate Process Chloride Process
Complexity of technology High complexity, most of the processes are periodic;
strict staff requirements
Extremely high complexity, most of the processes are
continuous; especially high staff requirements
Prevalence ~50% of products in the world ~50% of products in the world
Replaceability of products ~90% of chloride grades ~97% of rutile sulfate grades; does not replace anatase
sulfate grades
Quality of products High quality; brightness is slightly lower and yellowness
is higher in comparison with chloride grades
High quality; brightness is slightly higher and
yellowness is lower compared to chloride grades
Requirements for titanium-
containing raw materials
Ilmenite is used (40-60% TiO2 content), titanium slags Natural rutile, synthetic ilmenite, titanium slags are
used.
Production waste requiring disposal
(amount in brackets per 1 ton of
titanium dioxide produced)
‘Hydrolysis’ acid (6-8 tons), iron sulfate (2-3 tons if
ilmenite is used), sludge after decomposition (0.1
tons), liquid effluents (50-70 tons, including acidic
effluents )
Iron chloride (0.3-1.6 tons, depending on raw materials
used), liquid effluents (10-20 tons)
EBITDA 15-25% 15-25%
Extremely negative factor Moderately negative factor
Moderately positive factor Extremely positive factor
5. Existing practices for the utilization
of hydrolysis acid and acid wastes
from the sulfate process
Discharge into water: ocean, sea, river,
special lake, etc.
Drawbacks:
• Extremely negative environmental impact;
• Potential source of large-scale environmental
disasters;
• Currently prohibited in most countries of the world,
including China; in the last decade China’s
government has introduced extremely stringent
environmental restrictions and has banned
construction of new sulfate titanium dioxide
production plants.
The photo (above) and the map (below) show the acid lake of Crimea Titan, AR Crimea, Ukraine. Map source:
https://www.liga.net/economics/opinion/proklyatie-titana-katastrofa-sovetskogo-razliva
All titanium dioxide technologies in one place
6. Existing practices for the
utilization of hydrolysis acid and
acid wastes from the sulfate
process
Evaporation of acid from 25% to 68% as H2SO4 and its further
use for various needs, for example, in the production of
mineral fertilizers, or strengthening of the acid from 68% to
94% with concentrated sulfuric acid or oleum and its further
reutilization for ilmenite decomposition. This method is
unacceptable for acidic wastes with low concentration of
H2SO4, due to excessively high capital and operating costs.
Source: https://www.ecoplanning.fi/Documents/KBR_Ecoplanning_Brochure_Final.pdf
Drawbacks:
• Increased production cost (evaporated sulfuric acid is about
4-5 times more expensive than fresh sulfuric acid);
• Impossibility for most manufacturers to evaporate the entire
volume of hydrolysis acid due to the disbalance of flows; and
an attempt to solve the problem by evaporating to a higher
concentration leads to a significant increase in capital costs
and even greater increase in production cost.
• Generation of waste iron sulfate monohydrate with a high
content of free sulfuric acid, which requires disposal.
All titanium dioxide technologies in one place
7. Existing practices for the utilization
of hydrolysis acid and acid wastes
from the sulfate process
Neutralization with limestone and / or lime milk
and, as a result, formation of gypsum
Top photo: Venator plant, Scarlino, Italy, source: https://image.shutterstock.com/image-photo/chimney-industrial-
plant-producing-sulfuric-450w-127433285.jpg
Photo in the middle: Jinan Yuxing Chemical Co.Ltd plant, China, source: Google
Bottom photo: deposit of waste gypsum from Сinkarna TiO2 production plant, Slovenia. Source: Google.
Drawbacks :
• When the entire volume of hydrolysis acid formed is neutralized, a
huge amount of solid waste gypsum is produced, requiring further
utilization (~ 4-5 tons per 1 ton of titanium dioxide); Land disposal
of such amounts of waste is prohibited in some countries, for
example, in the EU, Directive 92/112 / EEC (Article 7) limits the
amount of gypsum waste to be discharged at the level not
exceeding 0.8 tons per 1 ton of titanium dioxide.
• Large areas are required for the disposal of solid waste (gypsum).
• Use of cheaper limestone increases the carbon footprint due to
CO2 emissions as a result of neutralization reaction, and the use of
more expensive lime milk significantly increases the cost of the
process.
All titanium dioxide technologies in one place
8. AITiO2ST™ – New Prospects for the
Development of Sulfate TiO2 Technology
• 2014 - RD Titan Group Innovative TiO2 team begins work on updated
sulfate technology
• Key objectives:
• ‘Green’ technology with minimal environment impact;
• Maximum energy efficiency;
• Implementation of ‘Smart factory’ approach, taking into account recent advances in the field
of automation and production management in keeping with Industry 4.0 concept (the fourth
industrial revolution);
• Creating a portfolio of high value-added products that make production flexible to changing
markets;
• Significant increase in economic numbers of production in comparison with conventional
sulfate and chloride technologies.
• 2018 – completion of the main phase of work on the development of
updated Advanced Innovative TiO2 Sulfate Technology (AITiO2ST™)
All titanium dioxide technologies in one place
9. AITiO2ST™: ‘Green’ Technology
All titanium dioxide technologies in one place
• Liquid wastes:
• No liquid wastes; complete processing of all liquid wastes,
implementation of ZLD (Zero Liquid Discharge) approach.
• Solid wastes:
• Formation of solid wastes of harmless and chemically neutral salts
after reverse osmosis (chemical composition: ions Na+, K+, Cl-, SO4
2-),
which are dumped to a special storage with a relatively small area;
prospectively, this waste can be considered as a raw material for the
production of anti-icing compounds, inorganic salts, etc.;
• No other solid wastes, including gypsum.
• Air emissions:
• Use of best European practices and solutions, compliance with the
standards adopted in the EU.
• Capture and oxidation of SO2 to SO3;
• Collection of sulfuric acid mist;
• Trapping of all kinds of dust.
• Carbon Footprint:
• Innovative technology for trapping ~ 40% of generated CO2 and, as a
result, an improved carbon footprint for all finished products produced
at the plant.
10. All titanium dioxide technologies in one place
AITiO2ST™: New Level of Energy Efficiency
• Water consumption:
• fresh water consumption is reduced by 2-2.5 times in comparison with conventional sulfate
technology;
• possibility of using water from artesian wells with high salinity (brackish water), which is
important for arid and desert areas with a shortage of fresh water;
• ‘smart’ system of filtrates reuse;
• recycling and reuse of wastewater.
• Natural gas consumption:
• use of advanced technologies in titanium dioxide production, ensuring minimal gas
consumption (1.5-2.3 times less compared to conventional sulfate process).
• Power consumption:
• ensuring own electric power production (up to 100% or more if needed);
• low cost of electricity (1.3-3.0 times lower than that offered on the market *).
• Superheated water vapor:
• ‘smart’ systems for maximizing steam energy use;
• use of secondary steam energy, which in a number of processes makes it possible to omit
the use of primary steam;
* depending on local conditions in a particular country
11. All titanium dioxide technologies in one place
• Automation and production management:
• Maximum automation and robotization (‘hands-off manufacturing’
concept) of all main production departments;
• Fully automated and robotic-aided packaging lines, warehouses,
finished products shipment terminals;
• Automation of higher levels of factory management (logistics,
procurement, sales, accounting, personnel management, customer
support, document management etc.);
• Low number of staff (in terms of 80 ktpa titanium dioxide
production plant):
• about 75 people for the titanium dioxide production shop with 80
ktpa capacity;
• about 400 people for the entire production;
• high level of staff motivation; regarding highly professional staff as
the highest value.
AITiO2ST™: Automation and Production
Management Inspired by Industry 4.0
12. All titanium dioxide technologies in one place
AITiO2ST™: Product Portfolio and Sales Share
# Finished Products Product Share in Total Sales (%)
Conventional
Sulfate
Technology
Conventional
Chloride
Technology
Updated Sulfate
Technology
AITIO2ST™
1 Titanium Dioxide 85-90 >90 50
2 By-products 10-15 <10 50
Revenue from
sales of all
products,
normalized to
classical sulfate
technology
1 ~0,9-1 1,7
The widest range of rutile titanium
dioxide grades, which makes it
possible to cover 90% of
applications (10 types of rutile
grades for paints&coatings,
plastics, decorative paper)
By-products with high added
value and a global high-
capacity market
Revenue from sales of all products
is 70-90% higher than revenue
from sales of products in the
classical sulfate and chloride
technologies
13. All titanium dioxide technologies in one place
AITiO2ST™: New Level of Economic Efficiency
5 5
6
20 20
45
0
5
10
15
20
25
30
35
40
45
0
1
2
3
4
5
6
7
Conventional Sulfate Technology Conventional Chloride Technology Updated Silfate Technology AITiO2ST™
CAPEX & EBITDA
CAPEX, $/kg EBITDA, %
14. Thank you
for your attention
www.innovativetio2.com
info@innovativetio2.com