METHODS AND APPARATUSES FOR PRODUCING METALLIC COMPOSITIONS VIA REDUCTION OF METAL HALIDES

摘要

Methods and apparatuses for producing a solid metallic composition by reacting a gaseous metal halide with a reducing agent are described. The method generally includes reacting a gaseous metal halide with a reducing agent in a manner effective to form a nonsolid reaction product, wherein the metal halide has the formula MXi, in which M is a metal selected from a transition metal of the periodic table, aluminum, silicon, boron, and combinations thereof, X is a halogen, i is greater than 0, and the reducing agent is a gaseous reducing agent selected from hydrogen and a compound that releases hydrogen, and combinations thereof; and solidifying the reaction product, thereby forming a metallic composition comprising M that is substantially free from halides. In another aspect, a method for producing a solid metallic composition is provided in which a metal subhalide is reduced by reaction with a gaseous reducing agent to form a nonsolid reaction product; which is then solidified to form a metallic composition comprising the metal that is substantially free from halides, oxygen, nitrogen, and carbon. An apparatus for producing a metallic solid composition is also provided that includes a source of a metal halide having the formula MXi; a source of a reducing agent wherein the reducing agent is a gaseous reducing agent selected from hydrogen and a compound that releases hydrogen, and combination thereof; a reactor in communication with the metal halided and the reducing agent sources, wherein the reactor provides conditions effective to carry out a gaseous reaction between the metal halide and the reducing agent to form a nonsolid reaction product; and a means for solidifying the reaction product to form a metallic composition comprising M that is substantially free from halides. The invention may be used to produce high-purity metallic compositions, particularly titanium particles and alloys thereof for use in powder metallurgy applications.