Sanjay Gangwar Saptarshi Sen Pritam Sarkar Contents
1 Resources 2 Grade Classification 3 Problems with Ore
4 Extraction Process 5 Scaling 6 Challenges
7 Top Producers 8 Properties 9 Applications
Major Sources of Tungsten
Scheelite Wolframite (CaWO4 ) [(Fe,Mn)WO4 ] Impurities- SiO₂ , Impurities- SiO₂ , Fe, Ca,P,Mo,Cu As Mn, As, Sn , S Reserves/Resources of W Worldwide Series 1 2500000
2000000 Reserves in metric
1500000 tons
1000000
500000
am
s n ia
a lia na
ie re ai ss ra i
r tn
Sp Ch
Ko
nt Ru st
ou Au
Vi
th
rC or N
he ot Source: https://ibm.gov.in/writereaddata/files/170989619465eaf20275d31Tungsten_2022.pdf Reserves/Resources of W in India Karnataka Rajasthan Andhra Pradesh Maharashtra
As per NMI data, as on Haryana, Tamil Nadu, Uttarakhand,West…
Maharashtra 1.04.2020 based on 11%
UNFC system- 89.43 million tonnes with Karnataka 41% Andhra Pradesh WO3 content of 1,44,650 17%
tonnes
Source: Rajasthan https://ibm.gov.in/writereaddata/files/170989619465eaf20275d31Tungsten_2022.pdf 27% Basis of Grade Classification WO₃ (tungsten trioxide) content 1. Saleable Grade Specifications concentrate with 65% or more WO₃ content - Saleable material. Lower-grade concentrates can be used for intermediate products if they are economically viable. 2. Minimum Economic Grade (India): In Degana, Rajasthan, and Chendapathar, West Bengal, the minimum economic grade of WO₃ content for saleable concentrate production is 0.1%.
3. WO₃ Content in Major Deposits
Balda, Sirohi District, Rajasthan: Average WO₃ content is between 0.24% and 0.48% Bankura, West Bengal: Average WO₃ content is approximately 0.1%. Udwarya, Sirohi District, Rajasthan: Average WO₃ content is 0.27%. Degana, Rajasthan: WO₃ content ranges from 0.09% to 1.62% across seven blocks. Source: https://ibm.gov.in/writereaddata/files/170989619465eaf20275d31Tungsten_2022.pdf Problems Associated with W Ore Complex Ore Processing Environmental Impact Health and Safety Hazards Costly Refinement and Purification Extraction Process Ore from mine Crushing & Milling Pre-concentration stage
Hydrometallurgy
Tungsten concentrate Ore beneficiation
Pyrometallurgy Tungsten metal,
Intermediate Tungsten trioxide, carbide or alloys Beneficiation Rationale High density difference between tungsten minerals and gangue Need to achieve high-grade concentrate for efficient chemical processing
Methods Gravity separation (jigs, spirals, tables) Magnetic separation for wolframite Flotation for scheelite Hydrometallurgy Simply making Wolframite ((Fe,Mn)WO4) and Scheelite (CaWO4) soluble in water Wolframite Processing
T = 450-550°C Rate-limiting step Formation of Tungsten Carbide Surface area dependent WO₂.₉ → WO₂ W + C → WC T = 550-650°C Fast reaction Blue oxide formation WO₂ → W T = 650-850°C Final reduction Particle size critical Challenges in the processes Impurity Co-extraction Mo⁶⁺ follows similar chemistry to W⁶⁺ pH selective precipitation Formation of heteropoly compounds Controlled redox conditions Selective complexing agents Polymerization nWO₄²⁻ + 2nH⁺ → (WO₃)n + nH₂O Temperature control pH maintenance Addition of stabilizing agents
Scale Formation Ca²⁺ + WO₄²⁻ → CaWO₄ (scale) Chelating agents addition Temperature control Regular acid cleaning Process Scaling Laboratory Scale (0.1-10 kg/day) Pilot/Bench Scale (10-100 kg/day) Industrial Scale (1-10 tons/day) Characteristics: Characteristics: Characteristics: Batch processing Semi-continuous operation Continuous operation Glass or small steel reactors Process validation Automated process control Manual operation Equipment testing Heat integration Focus on process optimization Data collection for scale-up Waste management systems Equipment: Equipment: Equipment: Small autoclaves Continuous reactors Large pressure vessels Laboratory furnaces Pilot filtration systems Industrial filtration systems Bench-scale filtration Semi-automated controls Automated material handling Small crystallizers Small industrial furnaces Industrial furnaces Crystallization plants Top Producers of Tungsten in the world •Top 5 Tungsten Producing Countries in the world :
Rajasthan 27% degana and balda mines Properties Of Tungsten Metal Resistance to High Temperature
High Density
Low Thermal Expansion
Corrosion Resistance
High ductility
High Luminous Efficiency
High wear Resistrance
What are the key applications and benefits of using tungsten metal In Different Fields?
1. Application of Tungsten in the Alloy Field :-
Steel : Tungsten has high hardness and high density, due to which it is is an important alloying element because it can significantly improve the strength, hardness, and wear resistance of steel and is widely used in the production of various steels.
Common Examples : high-speed steel, tungsten steel, and tungsten-
cobalt magnetic steel. used to manufacture , such as drills, milling cutters . Application of Tungsten in the Electronic Field
Tungsten has strong plasticity, low evaporation rate, high
melting point, and strong electron emission ability, so it is widely used in electronics and power supply industries.
For example, tungsten wires have high luminous efficiency
and long service life and are commonly used to manufacture various bulb filaments and iodine tungsten lamps. Application of Tungsten in the Medical Field
•Radiation Shielding: Tungsten is commonly used as a
radiation shield because of its high density, which effectively blocks radiation. It is used in therapy rooms and protective aprons.
•Dental Applications: Tungsten is also used in some dental
instruments, as well as in certain alloys for dental fillings. Application of Tungsten in the Military Field
•Because of its non-toxic and environmentally friendly
properties, tungsten has been used to make bullets to reduce the environmental pollution of military materials.
Manufacturing of military armour, guns and missiles
