Efficient preparation of metallic titanium from lower valence titanium chloride slurry by electrochemical reduction in molten salts.

Short extraction of metallic titanium by the electrochemical reduction process in molten salt has attracted increasing interest due to its many advantages. The electrolysis of high-purity titanium to produce lower valence titanium chlorides has so far been industrialized as balancing agents but large-scale production is still challenging due to the high cost of raw materials and easy deterioration. Herein, metallic titanium was extracted from lower valence titanium chlorides (LTCs) slurries by electrochemical reduction in molten salts. The results of LTC slurries at 260 ºC for 48 h revealed the formation of red-violet α - and γ - TiCl 3 with an Al content below 0.09 wt%, which gradually reduced to form metallic titanium in molten salt electrolytes. Porous metallic Ti powders were obtained from TiCl 3 by electrochemical reduction in KCl-LiCl-MgCl 2 molten salt at 400 °C. The reaction at the anode area was accompanied by TiCl 4 gas overflow, and continuous electrolysis of metallic titanium was achieved by supplementing the consumed TiCl 3. Overall, the proposed electrolysis process looks promising for large-scale applications due to its simple electrolysis equipment, relatively stable electrolyte components, and good product quality, thereby worth further future investigation. [Display omitted] • A new process for preparing metallic Ti from LTC slurries was successfully developed. • Atmospheric distillation can effectively separate TiCl 4 and AlCl 3 from LTC slurries to obtain pure TiCl 3. • The TiCl 3 raw material can be directly electrolyzed to yield high-quality metal titanium powder. [ABSTRACT FROM AUTHOR]