EPC general contract of Vietnam titanium slag smelter
Application of equipment:
The principle of producing titanium slag by electric furnace method is that ilmanite is mixed with solid reducing agent (coal or coke, etc.) in a certain proportion and added to the electric furnace for reduction melting, the iron oxide in the mineral is selectively reduced to metallic iron, and the titanium oxide is enriched into the slag, and the titanium slag and by-product metal iron are obtained after the slag iron separation.
Equipment composition:
Product flow diagram:
EPC site of titanium slag smelter in Vietnam and the scene of cooperation with your company:
The EPC (Engineering, Procurement, Construction) Project of Titanium Slag Smelter Equipment refers to a turnkey service system that integrates full-cycle responsibilities—from engineering design, equipment procurement, and on-site construction to commissioning and after-sales support—for titanium slag smelting facilities. Titanium slag, the primary raw material for titanium dioxide (TiO₂) and sponge titanium production, is smelted from ilmenite (titanium-iron ore) via high-temperature reduction. This EPC model provides clients with a one-stop solution to build efficient, environmentally compliant, and industrial-scale titanium slag smelting plants, bridging the gap between raw material supply and downstream titanium deep processing.
Core Definition & Scope of EPC Services
Unlike single-equipment supply, the EPC project covers the entire lifecycle of titanium slag smelter construction, with clear division of responsibilities across three core phases:
Engineering (E): Comprehensive technical design, including plant layout planning (considering material flow, energy supply, and safety distances), process flow design (ilmenite pretreatment → smelting → slag tapping → cooling), civil engineering design (foundation of smelting furnaces, workshops, and storage yards), and electrical/automation system design (power distribution, process control).
Procurement (P): One-stop sourcing of core equipment, auxiliary systems, and materials. This includes selecting and purchasing smelting furnaces, raw material pretreatment equipment, flue gas treatment systems, and high-temperature-resistant refractories, with strict quality control to ensure compatibility and reliability.
Construction (C): On-site implementation, covering civil construction (workshop erection, foundation pouring), equipment installation (furnace body assembly, pipeline connection), system commissioning (trial operation of smelting, cooling, and dust removal), staff training, and handover of the qualified plant to the client.
Key Process & Equipment Integration
Titanium slag smelting relies on high-temperature carbothermic reduction (1,600–1,800°C) to separate titanium from iron in ilmenite. The EPC project focuses on integrating the following core processes and equipment to ensure stable production:
1. Raw Material Pretreatment System
Process Objective: Remove impurities (moisture, clay, silica) from ilmenite and mix it with reducing agents (coke, anthracite) and fluxes (lime) to optimize smelting efficiency.
Key Equipment Integrated: Jaw crushers, ball mills, drying kilns, and automatic batching systems. The EPC team ensures matching of equipment capacity (e.g., 50–500 t/h batching speed) with the smelter’s designed output (typically 100–1,000 kt/a titanium slag).
2. Core Smelting System
Process Objective: Heat the mixed charge to molten state, where carbon reduces iron oxides to metallic iron (pig iron byproduct) and titanium remains in the slag phase (titanium slag, TiO₂ content 70%–95%).
Key Equipment Integrated:
Submerged Arc Furnace (SAF): The core smelting equipment, usually 16.5–33 MVA in capacity, with graphite electrodes and a refractory-lined furnace body. The EPC team customizes furnace power and size based on raw material properties and output requirements.
Electrode Lifting & Power Supply System: Matched transformers and automatic electrode regulators to maintain stable arc heating and avoid electrode breakage.
3. Slag/Iron Separation & Cooling System
Process Objective: Separate molten titanium slag (low density) and pig iron (high density) via gravity, then cool the slag to facilitate crushing and transportation.
Key Equipment Integrated: Slag tapping channels, iron tapping ladles, and water quenching/cooling beds. The EPC design ensures smooth tapping (to avoid slag-iron mixing) and rapid cooling (to prevent slag crystallization).
4. Environmental Protection & Energy Recovery System
Process Objective: Treat high-temperature flue gas (containing dust, SO₂, and CO) and recover waste heat to meet emission standards and reduce energy consumption.
Key Equipment Integrated: Cyclone dust collectors, bag filters, SO₂ scrubbers, and waste heat boilers (converting flue gas heat to steam for power generation or heating). The EPC project typically achieves dust removal efficiency >99.5% and SO₂ emission <50 mg/Nm³.
The EPC (Engineering, Procurement, Construction) Project of Titanium Slag Smelter Equipment refers to a turnkey service system that integrates full-cycle responsibilities—from engineering design, equipment procurement, and on-site construction to commissioning and after-sales support—for titanium slag smelting facilities. Titanium slag, the primary raw material for titanium dioxide (TiO₂) and sponge titanium production, is smelted from ilmenite (titanium-iron ore) via high-temperature reduction. This EPC model provides clients with a one-stop solution to build efficient, environmentally compliant, and industrial-scale titanium slag smelting plants, bridging the gap between raw material supply and downstream titanium deep processing.
Core Definition & Scope of EPC Services
Unlike single-equipment supply, the EPC project covers the entire lifecycle of titanium slag smelter construction, with clear division of responsibilities across three core phases:
- Engineering (E): Comprehensive technical design, including plant layout planning (considering material flow, energy supply, and safety distances), process flow design (ilmenite pretreatment → smelting → slag tapping → cooling), civil engineering design (foundation of smelting furnaces, workshops, and storage yards), and electrical/automation system design (power distribution, process control).
- Procurement (P): One-stop sourcing of core equipment, auxiliary systems, and materials. This includes selecting and purchasing smelting furnaces, raw material pretreatment equipment, flue gas treatment systems, and high-temperature-resistant refractories, with strict quality control to ensure compatibility and reliability.
- Construction (C): On-site implementation, covering civil construction (workshop erection, foundation pouring), equipment installation (furnace body assembly, pipeline connection), system commissioning (trial operation of smelting, cooling, and dust removal), staff training, and handover of the qualified plant to the client.
Key Process & Equipment Integration
Titanium slag smelting relies on high-temperature carbothermic reduction (1,600–1,800°C) to separate titanium from iron in ilmenite. The EPC project focuses on integrating the following core processes and equipment to ensure stable production:
1. Raw Material Pretreatment System
- Process Objective: Remove impurities (moisture, clay, silica) from ilmenite and mix it with reducing agents (coke, anthracite) and fluxes (lime) to optimize smelting efficiency.
- Key Equipment Integrated: Jaw crushers, ball mills, drying kilns, and automatic batching systems. The EPC team ensures matching of equipment capacity (e.g., 50–500 t/h batching speed) with the smelter’s designed output (typically 100–1,000 kt/a titanium slag).
2. Core Smelting System
- Process Objective: Heat the mixed charge to molten state, where carbon reduces iron oxides to metallic iron (pig iron byproduct) and titanium remains in the slag phase (titanium slag, TiO₂ content 70%–95%).
- Key Equipment Integrated:
- Submerged Arc Furnace (SAF): The core smelting equipment, usually 16.5–33 MVA in capacity, with graphite electrodes and a refractory-lined furnace body. The EPC team customizes furnace power and size based on raw material properties and output requirements.
- Electrode Lifting & Power Supply System: Matched transformers and automatic electrode regulators to maintain stable arc heating and avoid electrode breakage.
3. Slag/Iron Separation & Cooling System
- Process Objective: Separate molten titanium slag (low density) and pig iron (high density) via gravity, then cool the slag to facilitate crushing and transportation.
- Key Equipment Integrated: Slag tapping channels, iron tapping ladles, and water quenching/cooling beds. The EPC design ensures smooth tapping (to avoid slag-iron mixing) and rapid cooling (to prevent slag crystallization).
4. Environmental Protection & Energy Recovery System
- Process Objective: Treat high-temperature flue gas (containing dust, SO₂, and CO) and recover waste heat to meet emission standards and reduce energy consumption.
- Key Equipment Integrated: Cyclone dust collectors, bag filters, SO₂ scrubbers, and waste heat boilers (converting flue gas heat to steam for power generation or heating). The EPC project typically achieves dust removal efficiency >99.5% and SO₂ emission <50 mg/Nm³.
Key Features of EPC Projects
Compared to fragmented project execution (separate design, procurement, and construction), the EPC model for titanium slag smelters has distinct advantages:
- Turnkey Convenience: Clients only need to confirm technical requirements (output, titanium slag grade) and investment budget; the EPC contractor takes full responsibility for delivery, reducing coordination costs.
- Process Compatibility: Engineering design and equipment procurement are highly integrated—for example, the smelting furnace capacity is matched with the pretreatment system’s output, avoiding mismatches that cause production bottlenecks.
- Cost & Schedule Control: Centralized procurement reduces equipment costs by 10%–15%, and integrated construction management shortens the project cycle (typically 12–24 months for a 500 kt/a plant) compared to scattered execution.
- Compliance Assurance: The EPC team designs systems in line with national environmental standards (e.g., China’s “Emission Standards for Industrial Furnaces”) and local safety regulations, ensuring the plant passes acceptance upon completion.
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