In this paper, potassium salt roasting additives were applied to extract vanadium from vanadium–titanium magnetite concentrate. Meanwhile, the mechanisms of potassium salt roasting and acid leaching kinetics were investigated. The results indicate that potassium salt roasting additives are more efficient than sodium and calcium salt and that K₂SO₄ works best. Under certain conditions (a dosage of K₂SO₄ of 4 wt %, a roasting temperature of 900 °C, a roasting time of 1 h, a leaching temperature of 95 °C, a sulfuric acid concentration of 10% (v/v), and a leaching time of 1.5 h with a liquid to solid ratio of 3 mL/g) the vanadium leaching efficiency reached 71.37%, an increase of 30.20% compared to that of blank roasting. Additionally, XRD and related SEM-EDS analyses indicated that K₂SO₄ fully destroyed the structure of vanadium-bearing minerals such as magnetite, and promoted the generation of soluble KVO₃ to inhibit the formation of insoluble Ca(VO₃)₂ in the roasting process. Furthermore, it promoted the dissolution of sphene and the release of its vanadium in the leaching process, which increased the vanadium leaching efficiency significantly. Meanwhile, leaching kinetics analyses showed that the leaching process was controlled by internal diffusion; the apparent activation energy decreased from 37.43 kJ/mol with blank roasting to 26.31 kJ/mol with potassium salt roasting. The reaction order, with regards to the sulfuric acid concentration, decreased from 0.6588 to 0.5799. Therefore, potassium salt roasting could improve mineral activity, accelerating the leaching process and reducing the dependence on high temperature and high acidity.

In this paper, a novel K₂SO₄/KCl composite roasting additive was used to extract vanadium from vanadium–titanium magnetite concentrate. Further, the mechanism of K₂SO₄/KCl for extracting vanadium was studied. The results indicate that the vanadium leaching efficiency reached 82.04%, an increase of 7.43% compared to that of single K₂SO₄ and 10.05% compared to single KCl under the following conditions: a total dosage of K₂SO₄/KCl of 7 wt % with a mass ratio of 6/4, a roasting temperature of 950 °C, a roasting time of 1 h, a leaching temperature of 95 °C, a sulfuric acid concentration of 10% (v/v: volume percentage), and a leaching time of 1.5 h with a liquid-to-solid ratio of 3 mL/g. Moreover, crystal chemistry analyses indicated that the essence of the vanadium extraction with roasting was the conversion of cubic crystal systemic vanadium-bearing magnetite (FeO(Fe,V)₂O₃) to trigonal crystal systemic hematite (α-Fe₂O₃), and as most Fe(V)–O bonds were broken with the reconstructed conversion, the dissociation of V(III) occurred. Furthermore, the main decomposition products of K₂SO₄/KCl were K₂O, SO₂, and Cl₂. X-ray diffraction (XRD) and related SEM-EDS analyses indicated that there were mainly three aspects in the mechanism of K₂SO₄/KCl for extracting vanadium. Firstly, activated K₂O could combine with vanadium to generate soluble KVO₃ rather insoluble Ca(VO₃)₂; secondly, SO₂ could react with CaO to form CaSO₄ to prevent the generation of acid-consuming Ca(VO₃)₂, which was beneficial to the dissolution of vanadium-bearing sphene (Ca(Ti,V)SiO₄O); thirdly, Cl₂ could destroy the structure of hematite (Fe₂O₃) to reduce its wrapping extent to KVO₃.