A New Innovative Low Cost Manufacturing Process to Produce
Titanium All titanium is produced by the Kroll process, which is
a batch process for the magnesium (Mg) reduction of titanium
tetrachloride (TiCl4). Separate operations are required to
produce the toxic and very corrosive TiCl4, which must be stored
and transported. Magnesium also is produced separately in liquid
form via the electrolysis of magnesium chloride (MgCl2), which
requires storage and transport of liquid Mg as well as handling
the chloride gas produced. The Kroll-produced titanium sponge is
a 50-year-old mature process that is expensive, thus limiting
the utilization of titanium in spite of its most desirable
properties of light weight, corrosion resistance, and high
mechanical properties. A wholly new process is proposed to
produce titanium powder that utilizes the basic proven Kroll-
type chemistry but is performed in situ, which eliminates the
need for external sources of Mg and TiCl4. Because no separately
produced Mg or TiCl4 is require