An process for the preparation of high grade synthetic rutile from ilmenites with pig iron as a by-product

An improved process for the preparation of high grade synthetic retile from limonite with pig iron as a by-product, the said process comprising, subjecting limonite to reduction with 30-100% coal (w/w) at a temperature for a period of 2-6 hours, cooling and removing unreacted coal to obtain a product having 80-95% metallisation; smelting the metallised ilmenite mixed with less than 10% carbon (w/w) in a transferred arc plasma using arc current in the range of 100-400 amps, are voltage of 20-60 V under flow of inert gas at a range of 0 -2 litre/minute for a fixed time in the range 1-5 minutes; separating the metal as pig iron and TiO2 as slag; grinding the slag followed by oxidation in a temperature range of 500-1000°C in the presence of an oxidizing gas for 25-30 minutes, followed by leaching the oxidized product with dilute HCl at temperatures below 90°C for a period of 1-6 hours followed by filtration, washing and drying to obtain synthetic rutile