To improve the overall sustainability of MgO-based refractory production, a novel process to produce high purity MgO from calcined low-grade magnesite in ammonium chloride solution was developed. The process was designed on the basis of the phase equilibria of the NH 4 Cl-MgCl 2 -NH 3 -H 2 O system obtained using the Mixed Solvent Electrolyte model embedded in OLI software. The optimum calcination temperature of low-grade magnesite was determined to be 650 C in terms of the conversion ratio of magnesium and calcium in the leaching experiments. An apparent activation energy of Mg extraction was 30.98 kJ/mol, which is slightly lower than that of Ca leaching. An empirical kinetic model of magnesium extraction was also developed to describe the effects of NH 4 Cl concentration, particle size of calcined magnesite, and solid-to-liquid ratio on the extent of extraction of magnesium. At leaching time of 10 min, the leachate with high Mg/Ca molar ratio was obtained. Then, MgO with a purity of 99.09% was produced through the decomposition of intermediate 4MgCO 3 ÁMg(OH) 2 Á4H 2 O. V C 2015 American Institute of Chemical Engineers AIChE J, 61: 1933AIChE J, 61: -1946AIChE J, 61: , 2015 Keywords: kinetic, thermodynamic, solid-liquid reaction, low-grade magnesite, ammonium chloride
IntroductionMagnesite ore is the basic raw material for the manufacturing of MgO-based refractories. The explored magnesite reserves in China amount to about 3 3 10 10 tons in the 27 mining areas.1 About 87% of these resources are located in the Eastern part of Liaoning Province, China. There exist about 30 major producers of light-burned (caustic-calcined) and hard-burned magnesia from high grade magnesite, that is, magnesite with at least 45 wt % of MgO and a low content of silicate and calcium impurities (<2%). It is estimated that the annual production capacities of light-burned magnesia and hard-burned magnesia are about 2.7 3 10 6 tons and 3.3 3 10 6 tons, respectively. Unfortunately, low-grade magnesite, that is, magnestite with <44 wt % MgO and a high content of silicate and calcium impurities (>2%), is not fully utilized, which results in a large deposit of mineral tailings (fine powders). This limits the use of magnesite resources and also causes environmental issues. Therefore, an effective method of processing low-grade magnesite has been sought after to produce high value-added products, such as high purity MgO.Various methods of MgO production from low-grade magnesite have been proposed. Among these methods, the hydrometallurgical method is considered to be most effective in terms of energy and environmental standpoints.2 Different leaching agents, such as inorganic acids, 3-6 organic acids, [7][8][9][10][11][12] and inorganic salts [13][14][15][16] have been used for the dissolution of magnesium from magnesite or calcined magnesite. When inorganic acids, such as H 2 SO 4 , HNO 3 , or HCl, were used as leaching agents, some undesired impurities, such as Ca, Fe, Si, and Al, were also appreciably dissolved in the leaching process, whi...