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A Continuous Process to Produce Titanium Utilizing Metallothermic Chemistry

In the standard Kroll process reaction between the TiCl4 and Mg is at the reactor wall interface that limits the potential to design a continuous process. Many alternatives have been investigated over the past 70 years to engineer a continuous process utilizing metallothermic reduction of TiCl4. Approaches utilizing burner type architectures for continuous processing result in unacceptable very fine Ti powder. A unique process that operates continuously and produces controlled size powder that can be directly utilized in standard powder metallurgy, rapid manufacturing, or substituted for sponge will be discussed.