Vanadium-bearing muscovite is the most valuable component of stone coal, which is a unique source of vanadium manufacture in China. Numbers of experimental studies have been carried out to destroy the carrier muscovite’s structure for efficient extraction of vanadium. Hence, the vanadium location is necessary for exploring the essence of vanadium extraction. Although most infer that vanadium may substitute for trivalent aluminium (Al) as the isomorphism in muscovite for the similar atomic radius, there is not enough experimental evidence and theoretical supports to accurately locate the vanadium site in muscovite. In this study, the muscovite model and optimal location of vanadium were calculated by density functional theory (DFT). We find that the vanadium prefers to substitute for the hexa-coordinated aluminum of muscovite for less deformation and lower substitution energy. Furthermore, the local geometry and relative electronic properties were calculated in detail. The basal theoretical research of muscovite contained with vanadium are reported for the first time. It will make a further influence on the technology development of vanadium extraction from stone coal.

Process mineralogy shows that most vanadium in mica-type black shale exists in the octahedral sites of muscovite. The extraction of vanadium mainly occurs in the acid leaching process with participation of H ions. In this work, we firstly analyzed the dissolution rules of elements in acid leaching of muscovite, then adopted the density functional theory (DFT) calculation to accurately visualize the primary process of the surface corrosion of muscovite by H ions. The experimental results show that K releases the fastest and the release of Al is consistent with K. The simulation results find that the H preferentially shifts to the unsaturated structured O of the tetrahedron to form a strong 001 surface hydroxyl after replacing K, as well as relaxing the near Al(Si)–O bonds for the further removal of structural oxygen. Then, the 001 surface hydroxyls more likely participate in the dehydroxylation reaction through the reverse-path mechanism to remove the structural oxygen and break the hexagonal rings of the tetrahedral sheets. Remarkably, the formation and removal of structural water are overall endoergic, meaning that the disintegration of muscovite requires a sustained supply of heat. Further, the octahedral sheets where vanadium exists can be exposed to the acid environment for overall destruction. This detailed atomic migration process in acid leaching of black shale is visualized, which not only illuminates the reaction mechanism of H ions with the muscovite, but also provides guidance for vanadium extraction from black shale and a new concept for the destruction of other minerals.

In this paper, the extraction of vanadium from stone coal by roasting with MgO and leaching with sulfuric acid has been investigated, and the mechanism analysis of stone coal roasting with MgO was studied. The results indicated that under the conditions that the mass fraction of the particles with grain size of 0–0.074 mm in raw ore was 75%, the roasting temperature was 500 °C, the roasting time was 1 h, MgO addition was 3 wt %, the sulfuric acid concentration was 20 vol %, the liquid-to-solid ratio was 1.5 mL/g, the leaching temperature was 95 °C, and leaching time was 2 h, resulting in a vanadium leaching efficiency of 86.63%, which increased by 7.73% compared with that of blank roasting. The mechanism analysis showed that the degree of calcite decomposition was low and, thus, magnesium vanadate was more easily formed than calcium vanadate below 500 °C. Moreover, magnesium vanadate was easier to dissolve than calcium vanadate during the sulfuric acid leaching process. Thus, the vanadium leaching efficiency was enhanced by using MgO as a roasting additive below 500 °C. Additionally, at high temperature the formation of tremolite would consume calcium oxide produced from the decomposition of calcite, thus, the formation of calcium vanadate was hindered, and V₂O₅ would react with MgO to form magnesium vanadate. Therefore, the vanadium leaching efficiency of roasting with MgO was higher than that of blank roasting at high temperature.

During the acid leaching process of black shale, with the destruction of the aluminosilicate mineral structure, a large amount of aluminum (Al) is leached, accompanied by the release of vanadium (V). To separate aluminum from the vanadium-containing solution, the precipitation behavior of aluminum ions (Al³⁺) was investigated under hydrothermal conditions with the formation of alunite and natroalunite. In the solution environment, alunite and natroalunite are able to form stably by the Al³⁺ hydrolysis precipitation process at a temperature of 200 °C, a pH value of 0.4 and a reaction time of 5 h. When Al³⁺ was precipitated at a K/Al molar ratio of 1, the aluminum precipitation efficiency and the vanadium precipitation efficiency were 64.77% and 1.72%, respectively. However, when Al³⁺ was precipitated at a Na/Al molar ratio of 1, the precipitation efficiency of the aluminum decreased to 48.71% and the vanadium precipitation efficiency increased to 4.36%. The thermodynamics and kinetics results showed that alunite forms more easily than natroalunite, and the reaction rate increases with increasing temperature, and the precipitation is controlled by the chemical reaction. Vanadium loss increases as the pH value increases. It can be deduced that the ion state of tetravalent vanadium (VO²⁺) was transformed into the ion state of pentavalent vanadium (VO₂⁺) in the hydrothermal environment. The VO₂⁺ can be adsorbed on the alunite or natroalunite as a result of their negative surface charges, ultimately leading to vanadium loss.

A new effective method is proposed to prepare vanadium nitride (VN) via carbothermal reduction–nitridation (CRN) of the precursor, obtained by adding carbon black (C) to the stripping solution during the vanadium recovery from black shale. VN was successfully prepared at a low temperature of 1150 °C for only 1 h with a C/V₂O₅ mass ratio of 0.30 in N₂ atmosphere, but a temperature of 1300–1500 °C is required for several hours in the traditional CRN method. The low synthesis temperature and short period for the preparation of VN was due to the vanadium-coated carbon structure of the precursor, which enlarged the contact area between reactants significantly and provided more homogeneous chemical composition. In addition, the simultaneous direct reduction and indirect reduction of the interphase caused by the coating structure obviously accelerated the reaction. The phase evolution of the precursor was as follows: (NH₄)₂V₆O₁₆·1.5H₂O → V₂O₅ → V₆O₁₃ → VO₂ → V₄O₇ → V₂O₃ → VC → VN. The precursor converted to V₆O₁₃ and VO₂ completely after being calcined at 550 °C, indicating that the pre-reduction of V₂O₅ in the traditional CRN method can be omitted. This method combined the synthesis of VN with the vanadium extraction creatively, having the advantages of simple reaction conditions, low cost and short processing time.

A novel staged leaching process has been reported in this paper to selectively extract vanadium from roasted stone coal and the mechanisms have been clarified. Results showed that the leaching efficiency of V, Al, P and Fe was 80.46%, 12.24%, 0.67% and 3.12%, respectively, under the optimum dilute sulfuric acid dephosphorization (DSAD)-two-stage pressure acid leaching (PAL) conditions. The efficient separation of V from Fe, Al and P was realized. As apatite could be leached more easily than mica, the apatite could completely react with sulfuric acid, while the mica had almost no change in the DSAD process, which was the key aspect in realizing the effective separation of V from P. Similarly, the hydrolyzation of Fe and Al could be initiated more easily than that of V by decreasing the residual acid of leachate. The alunite and iron-sulphate compound generated in the first-stage PAL process resulted in the effective separation of V from Fe and Al.