| Summary: | The high content of iron in ilmenite ore poses a great challenge, particularly in the synthesis of titanium-containing products due to high susceptibility of iron (Fe) to corrosion. Direct leaching of ilmenite ore in hydrochloric acid (HCl) encouraging Fe dissolution was investigated. The influence of variable parameters, the use of additives, and the addition of metallic iron powder were studied to establish the optimum leaching parameters. The results showed that ilmenite with the particle size distribution of +150 µm yielded better efficiencies when leaching was performed with an acid concentration of 7.5 M and a solid-to-acid ratio of 1:10 at 90 °C. An agitation speed of 450 rpm yielded a superior Fe extraction of about 92.32% and a 2.40% titanium (Ti) loss. The addition of both metallic Fe and the MgSO<sub>4</sub> additive significantly enhanced Fe dissolution and decreased Ti recovery in a leach solution. It was found that leaching under optimum conditions produced a solid residue with 1.37% Fe impurity while 98.63% was extracted. The leached residue was comprised of 91.4% TiO<sub>2</sub> rutile phase and contained a high content of the ilmenite FeTiO<sub>3</sub> (4.37%) and SiO<sub>2</sub> (2.23%) impurities, while Al<sub>2</sub>O<sub>3</sub>, MgO, MnO<sub>2</sub>, CaO, V<sub>2</sub>O<sub>5</sub>, MnO<sub>2</sub>, and Cr<sub>2</sub>O<sub>3</sub> were below 0.13%. The high TiO<sub>2</sub> content in the leached residue makes it suitable for use as feed in the production of synthetic rutile. The leaching kinetics of Fe dissolution was found to conform to the shrinking core model, where diffusion through the product layer is rate controlling. The calculated activation energy according to the Arrhenius equation was 19.13 kJ/mol.
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