This study presents an effective and cleaner process with hydrogen-rich gases that uses oxidation roasting followed by gas-based direct reduction and melting separation to recovery iron, titanium, vanadium, and chromium from Hongge vanadium titanomagnetite (HVTM). The process parameters were systematically investigated and determined to be roasting temperature at 1200°C, roasting time of 15 min, reduction temperature at 1050°C, volume ratio of H2 to CO of 2.5, melting temperature at 1580°C, melting time of 30 min. Under optimized conditions, after melting separation, the recovery rates of iron, titanium, vanadium, and chromium were 97.9, 89.8, 96.7, and 97.8%, respectively. Furthermore, the melting separation mechanism was determined. The separated iron is a clean raw material for steelmaking and the Ti-rich slag can send for further processing to recover titanium. This study aims to provide a theoretical and technical basis for the comprehensive utilization of HVTM.
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