Ever since the discovery of vanadium in Mexican lead vanadate ore by Andrés Manuel del Rio in 1801, vanadium has been used in many fields, including the steel, aerospace, and chemical industries 1–5. The addition of 0.1–5.0-wt% vanadium to steel enhances the strength, hardness, and wear-resistance through grain refinement and carbide formation 6. Approximately 85% of vanadium consumption can be attributed to the production of high-strength low-alloy steel used in high-strength pipelines for oil and gas transportation 7,8. In addition, vanadium is also used in tool steels, such as cutting tools and working dies. Vanadium is widely used as an alloying element for the production of titanium alloys and nickel-based superalloys. The addition of vanadium to titanium alloys and superalloys can improve both the strength of an alloy and its creep resistance at high temperatures 1. For this reason, vanadium-containing non-ferrous alloys are generally used for the construction of airframes and the blades of jet engines 1. Approximately 10% of the overall vanadium consumption can be attributed to non-ferrous aerospace alloys 1,8. The remaining 5% of vanadium consumption is as vanadium pentoxide catalyst for the production of sulfuric acid and maleic anhydride in the chemical industry 8,9. Recently, vanadium has been considered for application to energy storage systems (ESSs) because of its various redox states, which are V2+, V3+, V4+, and V5+, in an aqueous solution 10. Relative to lithium-ion batteries that have caused several fires in ESS applications, vanadium redox flow batteries (VRFBs) offer cost, performance, rapid response, lifetime, and safety advantages for large-scale ESSs 11–13. With the increasing demand for renewable energy, the growing interest in the use of VRFBs for ESSs seems set to lead to a rapid increase in the demand for vanadium in the energy industry.
Vanadium is the 22nd most abundant element in the Earth’s crust and is more abundant than both copper and nickel 14,15. However, vanadium is not observed as a concentrated mineral but is widely dispersed as a result of the replacement of the Fe3+ and Al3+ sites 10,16. Vanadium is generally concentrated in magmatic titaniferous magnetite deposits or stone coal, wherein the V2O5 concentration is 0.2–1.0-wt% 17–22. However, owing to the high extraction costs and environmental restrictions, the production of vanadium from stone coal is limited 23. Currently, vanadiferous titanomagnetite (VTM) ore is the primary source from which vanadium is extracted.
Two major processes are used for the production of V from VTM 24,25. In the first process, a VTM concentrate is introduced into an electric-arc furnace (EAF) together with anthracite, which acts as a reducing agent. During the EAF process, the magnetite in the VTM is reduced to pig iron by a carbothermic reduction. The resulting pig iron contains approximately 3.5-wt% carbon and 1.2-wt% vanadium, whereas the smelter slag contains 32-wt% TiO2 and 0.9-wt% V2O5 6. The vanadium present in the pig iron is removed by oxygen blowing, resulting in the formation of a vanadium-rich slag. The final products of this process are low-carbon steel and vanadium-pentoxide-concentrated slag containing 20–25-wt% V2O5. After cooling, crushing, and magnetic separation, the vanadium is finally recovered from the V2O5-rich slag as ammonium polyvanadate through the application of alkali roasting and water leaching. An example of this is the Highveld process, as used in South Africa 6. In the second process, the VTM is concentrated through crushing, grinding, screening, and magnetic separation, and then alkali roasted with sodium carbonate in a rotary kiln. After water leaching, the vanadium dissolved in the water is precipitated through the addition of ammonium sulfate to produce ammonium poly- or meta-vanadate with a purity > 99.5%. An example of this process is the Xstrata process used in South Africa and Australia 6. A common aspect of both processes is the alkali roasting–leaching process. That is, the basic vanadium-extraction processes are similar, involving alkali roasting and water leaching. Therefore, understanding these processes is the key to successful vanadium extraction from VTM. In addition, the impurities that leach into the water in this process should be considered for application to VRFBs. The types of impurities and their concentrations in the electrolytes of VRFBs can affect the energy density, stability, and cell performance 26.
In Korea, VTM ores are deposited in the Yonchon Gwan-in mine (Gyeonggi Province) 27. The titanomagnetite ore bodies in Yonchon are associated with alkaline gabbroic rocks 28. In the magnetite matrix, titanomagnetite is distributed as exsolution textures of thin lamellae, with vanadium concentrated in the magnetite 29,30. The mineralogical characteristics, such as the associated rocks and their exsolution texture, vary with the region as a result of the differences in the original mineral formation. Therefore, the optimal conditions for vanadium extraction from Korean VTM ore would differ from the operational conditions applied to other conventional processes.
In the present study, the alkali-roasting and water-leaching processes for vanadium extraction from Korean VTM ore were studied. To achieve a high vanadium recovery efficiency, the optimal alkali roasting conditions, including temperature, time, and sodium carbonate concentration, were investigated, and thermodynamic calculations were performed. In addition, the effect of varying the temperature and time on the efficiency of the vanadium recovery in the water-leaching process was studied. The efficiencies with which other impurities, including silicon, aluminum, and sodium, could be extracted were also investigated.