Preparation of titanium powder using a combined method of aluminothermic reduction and molten salt electrolysis

In this study, aluminothermic reduction and molten salt electrolysis were combined to prepare titanium powder. In this combined method, titanium dioxide was first deoxidized to produce titanium–aluminum alloy through an aluminothermic reduction reaction, and then the titanium–aluminum alloy was separated through chloride molten salt electrolysis to generate titanium powder. The obtained titanium powder, titanium aluminum alloy and slag was analyzed using several techniques, including X-ray diffraction, X-ray photoelectron spectroscopy, and scanning electron microscopy. A mass ratio of 2:3 of titanium dioxide and aluminum was suitable for the production of titanium–aluminum alloys. A large amount of alumina generated through the aluminothermic reduction reaction was separated into slag phases using cryolite. Then, the phases were electrolyzed into aluminum and cryolite, which were reused as raw materials. The final titanium–aluminum alloy product was electrolyzed in a chloride molten salt system to separate titanium and aluminum and produce titanium powder. Therefore, the combination of thermal reduction and molten salt electrolysis is efficient and has great potential for producing high-purity titanium powder.