Recovery of niobium and titanium from low-grade niobium ores and the evaluation of Fe5Si3 alloy by-product as oxygen evolution reaction electrocatalysts

A low-grade ore containing 4 % niobium and 7 % titanium has been extracted from Bayan Obo tailing, but its potential has not been fully utilized. This study aims to recover the niobium and titanium elements from this low-grade ores in the form of their carbides. The process involves reducing niobium and titanium to (Nb,Ti)C through a carbothermal process. During this process, iron and silicon are also reduced to Fe-Si intermetallic compounds, allowing (Nb,Ti)C to diffuse into them. Subsequently, selective electrochemical oxidation is used to separate (Nb,Ti)C from the Fe-Si intermetallic compounds in an aqueous ferrous sulfate solution. The Fe-Si intermetallic compounds are first oxidized to the Fe 3 Si phase, and then to the Fe 5 Si 3 phase in the solution with pH 0.35. The (Nb,Ti)C/matrix interfaces are identified as the preferred site of electrochemical pitting corrosion. By exploiting the electrochemical oxidation reaction of iron in the matrix, (Nb,Ti)C powders are separated along these interfaces. The by-products of this process are FeSi alloys, which are evaluated for their electrocatalytic properties in oxygen evolution reactions. It is found that the Fe 5 Si 3 alloy by-product exhibits good electrocatalytic activity and kinetics in the oxygen evolution reaction, demonstrating its potential for practical applications.