4- THE MINERAL ILMENITE

Ilmenite is an economically important and interesting mineral. Ilmenite forms as a

primary mineral in mafic igneous rocks and is concentrated into layers by a process
called "magmatic segregation". It crystallizes out of a magma relatively early before
most of the other minerals. As a result, the heavier crystals of ilmenite fall to the bottom
of the magma chamber and collect in layers. It is these layers that constitute a rich ore
body for titanium miners. Ilmenite also occurs in pegmatites and some metamorphic
rocks as well as in the sedimentary rocks that are formed from the weathering and erosion
of them.

However, in sedimentary detrital deposits known as "placers", both minerals

rutile and ilmenite (which dominance in the titanium source) can be concentrated into
useable ores. Placers occur when a heavy, resistant mineral is mechanically and
gravitationally sorted by natural processes into a recoverable deposit. Placers occur in
river bends or behind river obstacles and in ocean shoreline sand deposits where slower
water currents allow the heavier minerals to settle. Placer deposits often contain both
rutile and ilmenite and there are enough of these deposits around the world to supply us
with titanium for decades if not centuries.

 Chemical Formula: FeTiO3, Iron Titanium Oxide

 Class: Oxides and Hydroxides
 Group: Hematite
 Subgroup: Ilmenite

These are the members of the Ilmenite Group

 Ecandrewsite (Zinc Iron Manganese Titanium Oxide)
 Geikielite (Magnesium Titanium Oxide)
 Ilmenite (Iron Titanium Oxide)
 Pyrophanite (Manganese Titanium Oxide)

Ilmenite is a metallic to submetallic mineral that is generally iron black. At times

it can form brightly lustered intricately faceted crystals or radial clusters arranged in a
rosette fashion.

Ilmenit is important source of titanium, it has been shown to be a strong

aluminum-like metal; light weight, non-corrosive, able to withstand temperature extremes
(especially its high melting point, 1800 degrees C) and it has good strength.

1
TITANIUM

Titanium) T: (Discovered in 1790, titanium is well known as a light metal with

excellent corrosion resistance.

Titanium sponge is the most basic form of titanium metal. Titanium metal is
consumed primarily in the commercial and military aerospace industries. Large-scale
production capacity of sponge exists in China, Japan, Kazakhstan, Russia, Ukraine, and
the United States.

Titanium is the ninth most abundant element, making up about 0.6% of the
Earth's crust. It occurs in nature only in chemical combination, usually with oxygen and
iron. Because of the high strength-to-weight ratio of its alloys and their resistance to
corrosion, titanium metal is an important strategic and critical material and is used widely
for high-performance military and civilian aircraft in both engines and airframes.

Mineral sources for titanium are rutile, ilmenite, and leucoxene, an alteration
product of ilmenite. Rutile is 93% to 96% titanium oxide (TiO 2), ilmenite may contain
between 44% and 70% TiO2, and leucoxene concentrates may contain up to 90% TiO 2. In
addition, a high-TiO2 slag is produced from ilmenite in Canada, Norway, and the
Republic of South Africa that contains 75% to 85% TiO2.

Only about 5% of the world's annual production of titanium minerals goes to

make titanium metal. The other 95% of such production is used primarily to make white
TiO2 pigment. Because of its whiteness, high refractive index, and resulting light-
scattering ability, TiO2 is the predominant white pigment for paints, paper, plastics,
rubber, and various other materials.

The United States has become highly dependent on imports of the minerals used
to make titanium and TiO2, which primarily comes from Australia and Canada.
Titanium is a metallic element that occurs in many minerals, however, only
ilmenite, leucoxene, and rutile have significant commercial value. Titanium metal alloys
are corrosion resistant and have a high strength-to-weight ratio. The density of titanium is
about 60% that of iron but it has comparable strength. Most titanium is not consumed in
its metal form but as titanium dioxide (TiO ), a white pigment in paints, paper, and
2

plastics. TiO is used as a pigment because of its whiteness, brightness, and opacity.
2

In 2002, numerous titanium mineral exploration and development projects were in

progress. World demand for TiO feedstock was estimated to be 4.6 million metric tons
2

(Mt), a slight increase compared with 2001. Europe and Asia led the slight increase in the
global demand for TiO pigment. Depressed demand from commercial aerospace markets
2

limited consumption of titanium metal.

2
World Review

World production of titanium mineral concentrates was 6.4 Mt (4.6 Mt of

contained TiO ). Australia, Canada, India, Norway, and South Africa continued to lead
2

the world’s production of titanium mineral concentrates (table 15). The largest
commercial producers of titanium mineral concentrates (in descending order) were Iluka
Resources, Richards Bay Iron and Titanium Pty. Ltd., QIT-Fer et Titane Inc., and Titania
A/S.
World TiO pigment production was estimated to be 3.98 Mt (Minerals Sands
2

Report, 2003c). France, Germany, Japan, the United Kingdom, and the United States
were the leading producing countries of TiO pigment. The largest commercial producers
2

of TiO pigment (in descending order) were DuPont, MIC, Huntsman Corp., Kerr-McGee,
2

Kronos Inc., and Ishihara Sangyo Kaisha, Ltd.

Titanium sponge was produced in China, Japan, Kazakhstan, Russia, Ukraine, and
the United States. Commercial ingot production capacity existed in France, Germany,
Japan, Russia, the United Kingdom, and the United States. Major producers of titanium
mill products were located primarily in China, France, Germany, Japan, Italy, Russia, the
United Kingdom, and the United States.

Outlook

During the next 5 years, global economic growth is expected to increase TiO 2

pigment consumption by about 3% per year. Because approximately 95% of all titanium
minerals are consumed to produce TiO pigment, consumption of titanium minerals is
2

expected to continue to follow a similar trend.

Demand for titanium metal by commercial aerospace producers is expected to
remain depressed for the immediate future. However, growth in airline passenger traffic
is expected to result in a 5% per year demand growth during the next decade. Demand for
titanium consumer goods, chemical process equipment, and military hardware is expected
to increase moderately during the next few years.

USES

Titanium alloys have found many applications in high tech airplanes, missiles,
space vehicles and even in surgical implants.

Additionally, titanium dioxide TiO2 is a white pigment that is used more and
more in paints as lead paint is discontinued due to health considerations. In fact, the
largest percentage (up to 95%) of world wide use for titanium is for the production of this
white pigment. The pigment has great luster, good endurance, high opacity (it hides
whatever is under it, important for paint) and a pure white color. The pigment is also used
to provide color for rubber, plastics, textiles, ink, cosmetics, leather, ceramics and paper.
Titanium and titanium compounds have found uses in desalination plants, electrical
components, glass products, artificial gemstones, jewelry and even as smoke screens.
Ilmenite is mined in Australia, Brazil, Russia, Canada, Sri Lanka, Norway, China, South
Africa, Thailand, India, Malaysia, Sierra Leone and the United States.

3
THE PHYSICAL CHARACTERISTICS OF ILMENITE:
 Color is black.
 Luster is metallic, submetallic to dull when tarnished.
 Transparency: Crystals are opaque.
 Crystal System: Trigonal; bar 3
 Crystal Habits include thin and thick tabular crystals with rhombohedral
truncations (similar to hematite's tabular habits); sometimes formed into rosettes.
Also granular and massive. Occurs as grains in placer sands.
 Cleavage is absent.
 Fracture is conchoidal or uneven.
 Hardness is 5 - 6
 Specific Gravity is 4.5 - 5.0 (average for metallic minerals).
 Streak is brownish black.
 Other Characteristics: Sometimes magnetic (will always become magnetic if
heated) and there is basal and rhombohedral parting.
 Associated Minerals include zircon, hematite, magnetite, rutile, spinel, analcime,
albite, apatite, monazite, calcite, natrolite, microcline, olivine, pyrrhotite, biotite
nepheline and quartz.
 Notable Occurrences are wide spread and include the type locality from where it
gets its name, Ilmen Lake in the Ilmen Mountains, Miask in the Southern portions
of the Ural Mountain Chain, Russia as well as Sweden; Germany; Froland,
Arendal and Kragero, Norway; Gilgit, Pakistan; Allard Lake and Mont Saint-
Hilaire, Quebec and Bancroft, Ontario, Canada; Finland; the Eastern Shores of
Australia and Brazil, Sri Lanka, China, Thailand, South Africa, India, Malaysia,
Sierra Leone and in Orange County and Essex County, New York; Iron Mountain,
Wyoming; Chester, Massachusetts; several sites in California and along the
eastern seaboard of the United States.
 Best Field Indicators are crystal habit, density, lack of cleavage, luster,
associations and streak.

Production

Mineral Concentrates.—Titanium mineral concentrates of economic importance

include ilmenite, leucoxene, rutile, slag, and synthetic rutile. Mining of titanium minerals
is usually performed using surface methods. Dredging and dry mining techniques are
used for the recovery of heavy-mineral sand deposits. Gravity spirals are used to separate
the heavy-minerals suite, while magnetic and high-tension separation circuits are used to
separate the heavy-mineral constituents. Ilmenite is often beneficiated to produce
synthetic rutile or titaniferous slag. Although numerous technologies are used to produce
synthetic rutile, nearly all are based on either selective leaching or thermal reduction of
iron and other impurities in ilmenite. Titaniferous slag with a TiO 2 content of up to 95% is
produced using pyrometallurgical processes.
Metal.—Titanium sponge is the raw form of titanium metal. Commercial production
involves the chlorination of titanium-containing mineral feedstocks to produce titanium
tetrachloride (TiCl ). Many producers reduce TiCl with magnesium to form titanium
4 4

sponge. Titanium ingot is produced by melting titanium sponge or scrap or a combination

of both, usually with various other alloying elements, such as aluminum

4
Global Events (2003):

 TITANIUM MINERAL CONCENTRATES

- The value of titanium mineral concentrates consumed in the United States in 2003
was about $500 million. The major co-product of mining from ilmenite and rutile
deposits was zircon. About 97% of titanium mineral concentrates was consumed
by domestic TiO2 pigment producers. The remainder was used in welding rod
coatings and for manufacturing carbides, chemicals, and metal.
- Imports for consumption (U.S.A): Ilmenite and slag rounded 565.000 metric tons
- Consumption, reported (U.S.A): Ilmenite and slag rounded 950.000 metric tons
- Price, dollars per metric ton:
Ilmenite, bulk, 54% TiO2, f.o.b. Australian ports: 93
Slag: 80% TiO2, f.o.b. Sorel, Quebec: 340
85% TiO2, f.o.b. Richards Bay, South Africa 408
Stocks, mine, consumer, yearend: Ilmenite 200
- Import Sources of United States (1999-2002): South Africa, 43%; Australia,
32%; Canada, 14%; Ukraine, 6%; and other, 5%.
- Events, Trends, and Issues: Global consumption of titanium mineral concentrates
was estimated to have increased slightly in 2003 compared with that of 2002. Domestic
consumption of titanium mineral concentrates was nearly unchanged. The United States
relied heavily on imports primarily from Australia and South Africa.
- On a global basis, declining ore grades of active mining operations have encouraged
the exploration and development for new sources of titanium minerals. Projects under
development include the following: Athabasca oil sands (Alberta, Canada), Corridor
Sands (Gaza, Mozambique), Douglas (Murray Basin, Australia), Kwale (Mombasa,
Kenya), Moma (Nampula, Mozambique), Pooncarie (Murray Basin, Australia), Truro
(Nova Scotia, Canada), and Wemen (Murray Basin, Australia).
- World Mine Production, Reserves, and Reserve Base of Ilmenite (rounded):
4,300 420,000 740,000 respectively
- World Resources: Ilmenite supplies about 90% of the world’s demand for titanium
minerals. World ilmenite resources total about 1 billion tons of titanium dioxide.

 TITANIUM AND TITANIUM DIOXIDE

- In 2003 (U.S.A), an estimated 55% of the titanium metal used was in aerospace
applications. The remaining 45% was used in armor, chemical processing, marine,
medical, power generation, sporting goods, and other non aerospace applications.
The value of sponge metal consumed was about $107 million, assuming an average
selling price of $6.50 per kilogram. The value of ingot produced from sponge and
scrap was estimated to be $215 million.
In 2003, titanium dioxide (TiO2) pigment, valued at about $2.8 billion. Estimated
use of TiO2 pigment by end use was paint (includes lacquers and varnishes) 53%;
plastic and rubber, 27%; paper, 15%; and other, 5%. Other uses of TiO 2 included
catalysts, ceramics, coated fabrics and textiles, floor coverings, printing ink, and
roofing granules.
- Salient Statistics—United States:
 Titanium sponge metal:

5
 Imports for consumption: 10,000 metric tons
Exports: 5,150 metric tons
Consumption, reported: 16,500 metric tons
- Price, dollars per kilogram, yearend: 6.50
- Stocks, industry yearend : 10,000 metric tons
 Titanium dioxide:
Production: 1,410,000 metric tons
Imports for consumption: 238,000 metric tons
Exports: 590,000 metric tons
Consumption, apparent: 1,070,000 metric tons
- Price, rutile, list, dollars per pound, yearend: 0.90
- Stocks, producer, yearend: 130,000 metric tons
- Import Sources of United States (1999-2002):
Sponge metal: Japan, 40%; Kazakhstan, 39%; Russia, 18%; and other, 3%.
Titanium dioxide pigment: Canada, 31%; Germany, 12%; France, 8%;
Spain, 6%; and other, 43%.
- Events, Trends, and Issues: Estimated domestic production of TiO 2 pigment was
1.41 million tons, nearly unchanged compared with that of 2002. Imports of TiO 2
pigment increased 3% compared with 2002, while exports increased 9%.
Apparent consumption of pigment decreased 4%. Capacity at several domestic
TiO2 pigment operations was being increased through process improvements.
Despite a plant closure in 2001, domestic TiO2 pigment capacity has increased by
about 100,000 tons per year since 1999.
Depressed sales of commercial aircraft continued to limit demand for titanium
metal. Domestic consumption of titanium sponge metal in 2003 decreased an
estimated 5% compared with that of 2002. Imports of titanium sponge metal
decreased by an estimated 7%.
- World Sponge Metal Production and Sponge and Pigment Capacity:
Sponge world production: 565,000 metric tons
Capacity (Operating capacity): Sponge 100,000 metric tons
Pigment 4,900,000 metric tons
- World Resources: Titanium for domestic sponge production was obtained from
rutile or rutile substitutes. The feedstock sources for pigment production were
ilmenite, slag, and synthetic rutile.

Reference: U.S. Geological Survey, Mineral Commodity Summaries, January 2004

6
 ABU GHALAGA ILMENITE

 LOCATION :
Lat . 24º 21 00`` N
Long . 35º 03` 15`` E
 Access :
The area lies 20 km SW of the red sea port of Abu Ghusun, 100 km south of
Mersa Alam town.

 Geology:
The Ilmenite deposit is confined to the Gabbro mass and forms a sheet - like
zone which strikes NW-SE and SE and dips approximately 30º to the NE. The
main ilmenite mass forms a big lens, with an exposed length of about 300 m, an
average width of about 150 m.
 Ore Description:
- Three main varieties of ore may be distinguished in the field
a) Red ore including surface ore - cap ore.(Oxidized, rounded 10% from
ore with average grade equal 39% TiO2)
b) Black ore. (Nonoxidized, rounded 90% from ore with average grade
equal 34% TiO2)
c) Disseminated ore.
- The average grain size of ilmenite is about 0.8 mm.
- Specific Gravity is 4.54 for Oxidized Ore and 4.39 for Nonoxidized
Ore.

 Mineral composition of ore deposit:

Ilmenite : 67.4 – 68.8
Primary hematite (exsolved) : 13 – 18%
Secondary hematite : 15%
Pyrite : 0.13 – 2.1%
Other minerals : 4 – 11%

7
Chemical Analyses of Abu Ghalaga Raw ore Samples

Above surface Under surface

Elements
from to from to
TiO2 37.09% 41.04% 33.89% 37.65%
Fe2O3 17.47% 23.00% 6.34% 23.85%
Fe O 27.93% 35.63% 25.94% 31.33%
SiO2 1.20% 7.76% 4.44% 7.90%
Al2O3 0.58% 1.92% 1.19% 5.34%
V2O5 0.31% 0.38% 0.29% 0.39%
Mn O 0.34% 0.97% 0.21% 2.20%
Mg O 0.54% 2.81% 0.87% 3.37%
Ca O 0.09% 0.75% 0.09% 0.75%
Na2O 1.88% 2.88% 1.15% 2.74%

 Method of mining:
Mining is mainly by open – pit method.

 Method of processing:
Physical methods such as gravity, magnetic, electrostatic or floatation are
mainly applied.
Although numerous technologies are used to produce Titaniferous slag with a
TiO2 content, the best way of processing by using pyrometallurgical processes.

 Reserves:
The estimated ore reserves based on diamond core drilling totaled 18 million
tons including 10 million tons of sure ore and 8 million tons of probable ore (The
average grade is 34.5% TiO2, which can be concentrate to 42-44% TiO2 With
Return rounded 80% by processing of crushing , girding, gravity, magnetic
separation ).

8
TABLE 7
PRICES FOR TITANIUM MATERIALS
2003 2004
Second Third Fourth First Second
quarter quarter quarter quarter quarter
Ilmenite, per metric ton, f.ob. Australian ports1 $85- $100 $85- $100
$80- $100 $80- $100 $80- $100
Titanium slag, per metric ton:2 409 397- 444 409- 444 404- 545 357- 464
Rutile, per metric ton, natural:1
Bagged, f.o.b. Australian ports 430- 540 430- 540 430- 540 452- 540
485- 550
Bulk, f.o.b. Australian ports 415- 445 415- 445 415- 445 434- 467 434-
467
Sponge metal, per pound, import2 3.22 3.16 3.01 3.01 3.40
Titanium scrap, per pound, turnings, unprocessed (Ti-6Al-4V)3 1.00-
1.05 1.20- 1.35 1.50- 1.70 2.80- 2.95 2.50- 2.55
Ferrotitanium, per pound, 70% (max. 4.5% Al) per pound Ti3 2.22- 2.25
2.40- 2.45 3.00- 3.20 5.40- 5.80 4.70- 5.10
Titanium dioxide pigment, per pound:4
Anatase, f.o.b. U.S. plants, list price .85- .95 .85- .95 .85- .95 .90- .95 .90-
.95
Rutile, f.o.b. U.S. plants, list
price .85- .90 .85- .90 .85- .90 .90- .95 .90- .95

9
 Ilmenite

Definition

   Ilmenite ore occurs in hard rock deposits enclosed within

titaniferous metagabbros in the Precambrian basement rock of the
South Eastern Desert.

Ilmenite among beach placers is given here under Black Sands.

Uses:

   It is used mainly to produce titanium white paints as well as the

titanium metal. The metal is essential industries as well as many
technologically advanced products.

Occurance:

  Abu Ghalaga, (latitude 24 21` 20`` N and longitude 35 03` 30`` is the
main ilmenite deposit in Egypt. Some other deposits are known a,but
are of a smaller reserves and poorer grade (e.g Hamra Dome, Um
Bisilla and other).

Properties

   The ilmeniten deposit occurs as an elongate lens within the upper

level of a sheet-like altered gabbro of Precambrian age.

   The deposite includes three ore types,red oxidized ore, black

nonoxidized ore and disseminated ore.

   The average grain size of ilmenite is about 0.4 mm.

   The ilmenite is characterized by high reflectivity, hardness and

high magnetic properties.

Reserves

   The estimated ore reserves based on diamond core drilling totalled

18 million tons,including 10 million tons of sure ore and 8 million
tons of probable ore.

Method of Mining

   Mining is mainly by open-pit method.

10
Method of preparation

   Physical methods such as gravity,magnetic,electrostatic or

floatation are mainly applied.

Infrastructure

   The area lies 17 km SW of the Red Sea port of Abu Ghusun, 100
km south of Mersa Alam town, approximately 240 km east Aswan.
The deposit area is not far from the Red Sea Coastal road and could
be easily supplied with water and electricity from Aswan.

Local Market:

   The local market production is about 53000 ton per year(1998). 

11