A feasibility study for high-temperature titanium reduction from TiCl4 using a magnesiothermic process

Abstract

The current industrial practice for titanium extraction is a complex procedure, which produces a porous reaction mass of sintered titanium particulates fused to a steel retort wall with magnesium and MgCl2 trapped in the interstices. The reactor temperature is limited to approx. 900 °C due to the formation of fusible TiFe eutectic, which corrodes the retort and degrades the quality of titanium sponge. Here we examine the theoretical foundations and technological possibilities to design a shielded retort of niobium-zirconium alloy NbZr(1%), which is resistant to corrosion by titanium at high temperature. We consider the reactor at a temperature of approx. 1150 °C. Supplying stoichiometric quantities of reagents enables the reaction in the gas phase, whereas the exothermic process sustains the combustion of the reaction zone. When the pathway to the condenser is open, vacuum separation and evacuation of vaporized magnesium dichloride and excess magnesium into the water-cooled condenser take place. As both the reaction and the evacuation occur within seconds, the yield of the extraction is improved. We anticipate new possibilities for designing a device combining the retort function to conduct the reduction in the gas phase with fast vacuum separation of the reaction products and distillation of magnesium dichloride.