Abstract
Tantalum powder production by magnesiothermic reduction of tantalum pentachloride (TaCl5) through an electronically mediated reaction (EMR) has been examined. Feed material, TaCl5, and reductant magnesium alloy were charged into electronically isolated locations in the molten salt (e.g. NaCl–KCl–MgCl2) at 1073 K. After providing external path for electron flow, the current flow between the feed and the reductant locations was monitored. A large current, more than 1 A, was detected during the reaction and tantalum powder with low nickel and silver content was obtained, although liquid Mg–Ag–Ni alloy was used as the reductant. This clearly demonstrates that tantalum powder can be produced by electronically mediated reaction (EMR) without direct physical contact between the feed (TaCl5) and the reductant (magnesium). The feasibility of tantalum reduction using Dy2+ ions dissolved in molten salt has also been demonstrated by utilizing molten salt containing DyCl2 as a reaction mediator. The mechanism of magnesiothermic reduction of TaCl5 in the molten salt is discussed using isothermal chemical potential diagrams.
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