Development of a Novel, Low-Cost Titanium Extraction Process for Bulk or Powder Applications

Abstract

UTRS Inc. has developed a novel two-step method to extract commercially viable titanium alloys (patent pending no. 20130164167 [1]). This approach has proven its potential to produce a variety of titanium alloys (Ti-6Al-4V, Ti_xAl_y, etc.,) and has demonstrated a number of advantages over the current commercial titanium production process. Additionally, the UTRS Process operates without producing CO₂ and eliminates the use of TiCl₄. Step 1: Aluminothermic reduction makes available many types of ores that could otherwise not be used. Due to the aluminothermic reduction technique and the composition of the ore, metal extracted from this step will inherently contain non-titanium elements. Step 2: Electro-refining removes undesirable elements from the thermally extracted titanium. This refined metal has a dendritic morphology with a wool-like appearance that is referred to as “titanium wool”. This new morphology of titanium allows it to have a diversity of end product types from titanium powder to bulk titanium.