Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.

Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.

Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is substantially free of oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.

Abstract: A method for producing a metal powder that combines molten reducing metal and metal halide in a space that is substantially free of oxygen and water, wherein the molten reducing metal is sodium and/or potassium, or aluminum (or magnesium or titanium) and is present in a stoichiometric excess to the metal halide which is a solid or liquid, thereby producing metal particles and salt, removing unreacted reducing metal, optionally removing the salt, and recovering the metal powder, is described. A method for producing a metal masterbatch wherein the molten reducing metal is aluminum, magnesium, and/or titanium and after combining molten aluminum (or magnesium or titanium) and metal halide in the reaction space, substantially removing the produced metal salt to obtain the metal masterbatch which comprises at least a portion of the molten aluminum (or magnesium or titanium) and at least one metal also is described.