Abstract: A process for producing titanium metal sponge from an exothermic reaction between titanium tetrachloride vapor and molten magnesium vapor, and reclaiming reactive metals from by-products of the exothermic reaction.

Abstract: A process for producing titanium metal sponge within a closed cell system involving the electrical decomposition of molten magnesium chloride into magnesium metal and chlorine gas within a closed cell to form said magnesium metal as a molten layer upon said magnesium chloride; terminating said electrolytic decomposition, and subsequently; directly contacting titanium tetrachloride with said layer of magnesium metal for effecting a reduction reaction therebetween within the same closed cell to form titanium metal sponge and magnesium chloride and removing said titanium metal sponge from said closed cell. The chlorine gas by-product can be used to form titanium tetrachloride from a titanium ore/coke mixture.

Abstract: An apparatus including a single electrolytic/reaction cell, for extraction of titanium sponge from rutile ore. Magnesium chloride is electrolytically separated into magnesium metal and chlorine gas within the cell. The chlorine gas produced is reacted with rutile ore and coke to produce titanium tetrachloride in a separate chlorinator and the product is directed to the cell subsequent to completion of electrolysis. Titanium tetrachloride is reacted with magnesium metal in the same cell where the magnesium is produced to form titanium sponge and magnesium chloride. The titanium sponge is separated within said cell with the magnesium chloride being recovered and recycled. Major impurities are separated by distillation. Plural electrolytic cells can be coupled to a single chlorinator in a continuous process. Very pure titanium sponge is produced with this self-replenishing process.