As the global energy transition accelerates, vanadium—often referred to as the “vitamin of metals” and the “MSG of modern industry”—is experiencing unprecedented demand growth. In addition to its indispensable role in steelmaking, chemicals, aerospace, and pharmaceuticals, vanadium redox flow batteries (VRFBs) have emerged as one of the most promising technologies for large-scale energy storage. The global VRFB market is expected to reach several billion dollars in the coming years. With vanadium becoming increasingly important in the new energy landscape, the efficient and environmentally friendly extraction and purification of vanadium resources has become a major focus of the industry.

Acid Leaching for Vanadium Recovery: Mainstream Technology Facing Separation Challenges

Vanadium-bearing stone coal resources around the world are generally characterized by low grades and complex compositions, which directly limit vanadium utilization efficiency. At present, acid leaching processes (either direct acid leaching or acid leaching after roasting) have become the primary direction for vanadium extraction due to their strong adaptability, high leaching efficiency, and relatively low environmental impact. However, acid leach solutions typically contain low concentrations of vanadium along with various impurity ions. Efficient separation and enrichment of vanadium from these solutions remain the key technical challenges.

Currently, three major methods are used for vanadium recovery from acid leach solutions:

Chemical Precipitation: This method is simple to operate, but it often results in vanadium losses. In addition, precipitating agents may introduce new impurities, affecting the purity of the final product.

Ion Exchange: Ion exchange offers relatively good selectivity; however, the limited exchange capacity and susceptibility of resins to poisoning have gradually reduced its industrial application.

Solvent Extraction: With advantages such as excellent selectivity, high extraction efficiency, superior product purity, and large processing capacity, solvent extraction has become a major focus of both research and industrial applications.

Core Equipment for Solvent Extraction: CWL-M Centrifugal Extractor

Developed independently by Zhengzhou Tiei Extraction Technology Co., Ltd., the CWL-M Series Centrifugal Extractor is a new-generation, high-efficiency, energy-saving, and fully automated extraction and separation system. The equipment has been successfully applied and validated in multiple vanadium recovery projects worldwide, significantly improving vanadium recovery rates and product quality.

Vanadium Recovery Process from Acid Leach Solutions

1.Acid Leach Solution Pretreatment: Vanadium-bearing stone coal is subjected to crushing, roasting (or direct acid leaching), leaching, and solid-liquid separation to produce a vanadium-containing acid leach solution.

2.Extraction: The acid leach solution and organic extractants (such as P204 or P507) are fed into the CWL-M Centrifugal Extractor at a specified ratio. Utilizing the high centrifugal force generated by rapid rotation, the centrifuge enables intensive mixing and instantaneous mass transfer between the aqueous and organic phases. Vanadium is selectively extracted into the organic phase.

3.Scrubbing: The loaded organic phase enters the scrubbing stage, where it is mixed with a scrubbing solution to remove co-extracted impurities such as iron, aluminum, and phosphorus.

4.Stripping: The scrubbed organic phase is mixed with a stripping agent (such as dilute sulfuric acid) inside the centrifugal extractor. Vanadium is stripped from the organic phase back into the aqueous phase, producing a vanadium-rich solution.

5.Downstream Processing: The vanadium-rich solution is further processed through precipitation, calcination, and other refining steps to produce high-purity vanadium pentoxide (V₂O₅).

6.Organic Phase Regeneration: After stripping, the regenerated organic phase is recycled back to the extraction stage for continuous reuse.

The entire process can be configured in multi-stage counter-current or cross-current flow arrangements. By connecting multiple CWL-M Centrifugal Extractors in series or parallel, continuous, stable, and fully automated production can be achieved, maximizing vanadium recovery efficiency while reducing operating costs.

Core Advantages of the CWL-M Centrifugal Extractor in Vanadium Recovery

1.Simple Structure and Stable Operation
The CWL-M Centrifugal Extractor adopts an upper-suspended single-pivot design. The equipment is free of bottom bearings and mechanical seals, eliminating the risk of leakage. This design effectively solves common problems associated with conventional centrifugal extractors, such as frequent failures and short service life, while significantly reducing maintenance costs.

2.Low Energy Consumption and High Throughput
With its unique impeller and drum design, the CWL-M Centrifugal Extractor provides high processing capacity per unit. Its energy consumption is significantly lower than that of traditional mixer-settlers or extraction columns, substantially reducing the production cost per ton of vanadium.

3.Fully Fluoropolymer Construction for Superior Corrosion Resistance
Components that come into contact with acid leach solutions (containing high concentrations of sulfuric acid, hydrochloric acid, and fluoride ions) are manufactured from fully fluoropolymer materials such as PTFE and PFA. These materials offer outstanding corrosion resistance, extend equipment service life, and prevent contamination from metal ions.

4.Rapid Mixing and Separation with High Stage Efficiency
Intensive mixing and high-speed centrifugal separation are completed within the drum. The residence time is only a few seconds to several tens of seconds, while stage efficiency can exceed 95%. This effectively prevents vanadium hydrolysis and emulsion formation during the extraction process.

5.Adjustable Weirs and Low Liquid Hold-Up
The diameter of the weir can be adjusted to precisely control the phase ratio and separation performance. The equipment features a very low liquid hold-up volume, reducing organic phase inventory and material retention. This makes it particularly suitable for valuable materials and high-cost solvent systems.

6.Fully Automatic Continuous Operation with Strong Process Adaptability
The system supports both local and remote DCS control and can automatically adjust operating parameters such as rotational speed, flow rate, and phase ratio. Continuous 24-hour operation can be achieved with minimal operator intervention.
For acid leach solutions derived from vanadium-bearing stone coal, which are typically characterized by low vanadium concentration, high impurity content, and a tendency toward emulsification, the CWL-M Centrifugal Extractor demonstrates excellent adaptability and operational stability.

Significant Economic and Environmental Benefits

Compared with conventional extraction processes, a vanadium recovery plant built around the CWL-M Centrifugal Extractor can:

1.Increase vanadium extraction efficiency to over 98%, reducing vanadium losses in tailings.
2.Reduce extractant consumption by 30%–50%, minimizing solvent entrainment losses.
3.Save more than 60% of installation space under equivalent processing capacities.
4.Enable closed-system operation, reducing VOC emissions and wastewater discharge while complying with increasingly stringent global environmental regulations.

Zhengzhou Tiei Extraction Technology Co., Ltd. specializes in the research, design, and manufacture of liquid-liquid extraction and separation equipment. The company possesses comprehensive process laboratories, pilot-scale testing platforms, and full industrial manufacturing capabilities. The CWL-M Series Centrifugal Extractor is available in configurations ranging from laboratory-scale units to industrial systems capable of processing tens of thousands of tons annually. Tiei Extraction also provides one-stop services covering process development, flow sheet design, equipment integration, commissioning, and operational support.

For more technical specifications, sample testing, or customized extraction solutions, please feel free to contact us.
Email: sales@tieiextraction.com
Whatsapp: +86 19069612820