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: The present disclosure provides a purification material for a rare earth metal or rare earth alloy and a preparation method thereof and a purification method for a rare earth metal or rare earth alloy. The purification material includes the following raw materials in mass percentage: 30% to 45% of a tungsten powder, 30% to 50% of a rare earth oxide, 5% to 10% of zirconia, 10% to 15% of a binder, and 1% to 5% of a rare earth hydride.

Abstract: Methods and systems for separating a first metal from a metal-containing feed stream are provided. The method can include applying solar energy, for example, by focusing one or more mirrors in one or more heliostats, to heat a metal-containing feed stream in a heating zone to a first temperature to produce a first vapor including the first metal. The first vapor can be condensed in a condensation zone to produce a first liquid including the first metal, and the first liquid can be collected. The system can include a separation unit include a heating zone in fluid communication with a condensation zone and a means for applying solar energy to heat a metal-containing feed stream disposed in the heating zone.

Abstract: The present disclosure broadly relates to a process for recovering scandium and/or vanadium values from various feedstocks. More specifically, but not exclusively, the present disclosure relates to a process for the selective recovery of scandium and/or vanadium values from a feedstock, the process comprising: leaching the feedstock in a sulfuric acid solution while simultaneously sonicating the sulfuric acid solution thereby producing a pregnant solution; and selectively removing scandium and vanadium compounds from the pregnant solution using a solvent extraction process.

Abstract: Disclosed is a method for preparing vanadium or vanadium alloy powder from a vanadium-containing raw material through a shortened process, including: calcinating a mixture of a vanadium-containing raw material and an alkali compound for oxidation to form a water-soluble vanadate; purifying the vanadate followed by vanadium precipitation to produce an intermediate CaV2O6 with high purity; dissolving CaV2O6 in a molten-salt medium together with other raw materials to form a uniform reaction system; and introducing a reducing agent to the system followed by separation, washing and drying to produce vanadium or vanadium alloy powder having a particle size of 50-800 nm and a purity of 99.0 wt % or more. The method can continuously process vanadium-containing raw materials to prepare vanadium or vanadium alloy powder.

Abstract: The invention provides tantalum alloys, methods for forming tantalum alloys having a luminous, black, ceramic surface, and articles, such as, but not limited to, jewelry and watches, formed from the tantalum alloys.

Abstract: A separation and recovery method that enables titanium and tungsten to be separated and recovered from a used DeNOx catalyst in high yield. Specifically, a method of separating and recovering metal elements that includes a first heating step of heating a DeNOx catalyst containing titanium, tungsten, vanadium and iron in a chlorine atmosphere, thereby removing the vanadium and the iron from the DeNOx catalyst, and a second heating step, performed after the first heating step, of heating the DeNOx catalyst in a chlorine atmosphere while the catalyst is exposed to a gas of a hydrocarbon compound (excluding CH4) or an oxygen-containing carbon compound, thereby volatilizing the tungsten and the titanium from the DeNOx catalyst, and recovering the tungsten and the titanium from the DeNOx catalyst.

Abstract: A ductile alloy is provided comprising molybdenum, chromium and aluminum, wherein the alloy has a ductile to brittle transition temperature of about 300 C after radiation exposure. The invention also provides a method for producing a ductile alloy, the method comprising purifying a base metal defining a lattice; and combining the base metal with chromium and aluminum, whereas the weight percent of chromium is sufficient to provide solute sites within the lattice for point defect annihilation.

Abstract: Process for the production of valve metal powders, in particular niobium and tantalum powder, by reduction of corresponding valve metal oxide powders by means of vaporous reducing metals and/or hydrides thereof, preferably in the presence of an inert carrier gas, wherein the reduction is performed at a vapor partial pressure of the reducing metal/metal hydride of 5 to 110 hPa and an overall pressure of less than 1000 hPa, and tantalum powder obtainable in this way having a high stability of the powder agglomerate particles.

Abstract: Processes comprising: melting a mixture comprising a valve metal precursor and a diluting agent in at least one first vessel under a first set of temperature and residence time conditions; transferring the mixture to at least one second vessel; and initiating, in the at least one second vessel, a reaction of the valve metal precursor to form a valve metal under a second set of temperature and residence time conditions; valve metal powder prepared thereby and uses therefor.

Abstract: Provided herein are materials that can achieve up to 14% hydrogen absorption by weight in ambient conditions, which is a marked improvement over the hydrogen absorption values found in the prior art. Further provided are experimental conditions necessary to produce these materials. In order to produce the hydrogen storage material, a transition metal (or Lithium) is vaporized in a pi bond gas in conditions that permit only a few bonding collisions to occur between the vaporized transition metal atoms and pi bond gas molecules before the resulting bonded material is collected.

Abstract: One aspect is a method for producing an alloy, whereby the alloy consists of a first metal, a second metal, a third metal, and a fourth metal, and the first metal, the second metal, the third metal, and the fourth metal are selected from the group consisting of the metals, niobium, zirconium, tantalum tungsten. The method includes the steps of grinding the first metal to form a first metal powder and grinding the second metal to form a second metal powder; mixing the first metal powder and the second metal powder to form a first blended powder; generating a first blended body from the blended powder by a powder metallurgical route; and generating the alloy by melting the first blended body and the remaining metals by a melt metallurgical route.

Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

Abstract: In the method for recovering a metal from a target that contains a metal and a metal oxide, the target contains a sintered body of the metal oxide after being heated under a condition of melting the metal without melting or decomposing the metal oxide. The target is heated in an upper crucible of a two-level crucible that includes the upper crucible with a through hole-formed in a bottom surface thereof, and a lower crucible disposed below the through hole, the size of the through hole being set such that it does not allow the sintered body of the metal oxide contained in the target to pass therethrough, and the melted metal is caused to flow into the lower crucible, so that the metal is separated from the metal oxide.

Abstract: This invention relates to a process that utilizes high-temperature oxidation with controlled stoichiometry in the concentration of vanadium from carbonaceous feedstock materials containing vanadium, such as residues, ashes and soots resulting from the combustion or gasification of petroleum vacuum residuum, petroleum coke, kerogen from oil shale, and bituminous sand, e.g., tar sand or oil sand, or extra heavy oil or other carbonaceous feedstocks that contain vanadium. A preferred embodiment uses a counter-rotating vortex reactor and a cyclonic, entrained-flow reactor to rapidly heat and oxidize feedstock at temperatures in the range of about 2100° F. to 2900° F., resulting in a vapor stream with entrained, solid materials comprising the concentrated vanadium species.

Abstract: A process for the selective recovery of Mo, V, Ni, Co and Al from spent hydroprocessing catalysts includes the steps of treating the spent catalysts to recovery metals, support as well as chemicals. The process steps include deoiling, decoking, washing, dissolving, complexing agent treatment, acid treatment and solvent extraction. This process uses limited steps than conventional processes by the use of ultrasonic agitation for metal extraction and the presence of a chelating agent particularly Ethylene Diamine Tetra-Acetic Acid (EDTA). The process also discloses the compete recovery of the extracting agent EDTA with high purity for reuse.

Abstract: Provided is a roasting method capable of reducing both C and S components in minerals down to 0.5% or less, respectively, and securing a yield ratio of 90% or more for the Mo component. In a rotary kiln 7, a V, Mo and Ni containing material containing C and S components is subjected to oxidizing roasting to remove the C and S components from the material before reducing the material by means of a reducing agent in order to recover valuable metals composed of V, Mo and Ni. The rotary kiln is equipped with a burner 11 disposed on a material charge side 8a of the roasting furnace 8 to which the material is charged. In the roasting furnace, a direction along which the material moves and a flow of oxygen-containing gas introduced into the roasting furnace 8 are set to be parallel with each other.

Abstract: A reduction treatment apparatus can include a reduction furnace configured to reduce zinc and/or iron oxide through heat treatment of zinc-containing iron oxide or zinc oxide or iron oxide, with a reducing material. The reduction treatment apparatus also has an oxide inlet configured to supply to the reduction furnace the zinc-containing iron oxide or zinc oxide or iron oxide. The reduction treatment apparatus further has a reducing material inlet configured to supply to the reduction furnace the reducing material. The reducing material can comprise at least one of ASR, shredder dust of home electric appliances, waste plastics, refuse derived fuel, refuse paper and plastic fuel, sludge, oil mud, chips of wood, thread debris, rubber debris, and animal and plant residues. The reduction furnace can be configured to use the reducing material as a heating material and reduce the zinc-containing iron oxide or zinc oxide or iron oxide without auxiliary fuel.

Abstract: One aspect relates to a method for producing an alloy, whereby the alloy consists of three metals and the three metals are selected from the group consisting of tantalum, tungsten, and niobium. The method according to one embodiment is characterized by a) grinding the tantalum to form a tantalum powder and grinding the tungsten to form a tungsten powder; b) mixing the tantalum powder and the tungsten powder to form a blended powder, whereby the weight fraction of tungsten powder in the blended powder is larger than in the desired alloy; c) producing a blended body from the blended powder by means of a powder metallurgical route; d) producing a pre-alloy by means of a first melting of the blended body and at least a fraction of at least one further metal by means of a melt metallurgical route; and e) producing the alloy by means of a second melting of the pre-alloy and the remaining fraction of at least one metal by means of a melt metallurgical route.

Abstract: In the method for recovering a metal from a target that contains a metal and a metal oxide, the target contains a sintered body of the metal oxide after being heated under a condition of melting the metal without melting or decomposing the metal oxide. The target is heated in an upper crucible of a two-level crucible that includes the upper crucible with a through hole-formed in a bottom surface thereof, and a lower crucible disposed below the through hole, the size of the through hole being set such that it does not allow the sintered body of the metal oxide contained in the target to pass therethrough, and the melted metal is caused to flow into the lower crucible, so that the metal is separated from the metal oxide.

Abstract: One aspect discloses a method for producing an alloy, whereby the alloy consists of a first metal, a second metal, a third metal, and a fourth metal, and the first metal, the second metal, the third metal, and the fourth metal are selected from the group consisting of the metals, niobium, zirconium, tantalum, and tungsten, and the method includes the steps of a) grinding the first metal to form a first metal powder and grinding the second metal to form a second metal powder; b) mixing the first metal powder and the second metal powder to form a first blended powder; c) generating a first blended body from the blended powder by means of a powder metallurgical route; d) generating the alloy by melting the first blended body and the remaining metals by means of a melt metallurgical route.

Abstract: A niobium or niobium alloy which contains pure or substantially pure niobium and at least one metal element selected from the group consisting of Ru, Rh, Pd, Os, Ir, Pt, Mo, W and Re to form a niobium alloy that is resistant to aqueous corrosion. The invention also relates to the process of preparing the niobium alloy.

Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

Abstract: Provided herein are materials that can achieve up to 14% hydrogen absorption by weight in ambient conditions, which is a marked improvement over the hydrogen absorption values found in the prior art. Further provided are experimental conditions necessary to produce these materials. In order to produce the hydrogen storage material, a transition metal (or Lithium) is vaporized in a pi bond gas in conditions that permit only a few bonding collisions to occur between the vaporized transition metal atoms and pi bond gas molecules before the resulting bonded material is collected.

Abstract: The present invention provides a process for manufacturing a porous metal electrode, wherein the porosity degree is in the range of 30 to 50% and the metal is capable of forming a stable, uniform, oxide layer having a dielectric constant greater than 25 (k?25), preferably selected from the group consisting of tantalum and niobium, comprising a substantially uniform porous layer of deposited said metal particles thereon. The present invention further relates to a stable suspension for electrophoretically homogeneously deposition of said metal.

Abstract: High purity tantalum metals and alloys containing the same are described. The tantalum metal preferably has a purity of at least 99.995% and more preferably at least 99.999%. In addition, tantalum metal and alloys thereof are described, which either have a grain size of about 50 microns or less, or a texture in which a (100) intensity within any 5% increment of thickness is less than about 15 random, or an incremental log ratio of (111):(100) intensity of greater than about ?4.0, or any combination of these properties. Also described are articles and components made from the tantalum metal which include, but are not limited to, sputtering targets, capacitor cans, resistive film layers, wire, and the like. Also disclosed is a process for making the high purity metal which includes the step of reacting a salt-containing tantalum with at least one compound capable of reducing this salt to tantalum powder and a second salt in a reaction container.

Abstract: Processes comprising: melting a mixture comprising a valve metal precursor and a diluting agent in at least one first vessel under a first set of temperature and residence time conditions; transferring the mixture to at least one second vessel; and initiating, in the at least one second vessel, a reaction of the valve metal precursor to form a valve metal under a second set of temperature and residence time conditions; valve metal powder prepared thereby and uses therefor.

Abstract: A treatment apparatus (10) includes a liquid reactant metal containment vessel (11) for containing a first liquid reactant metal and isolating the reactant metal from the atmosphere. A release chamber (14) is adapted to receive the first liquid reactant metal from the containment vessel (11) and a submerging arrangement (21) is adapted to dunk or submerge a container (46) of feed material into the liquid reactant metal and move the container to a release location within the release chamber (14). Relatively light materials rising from the submerged container (46), including unreacted feed material, intermediate reaction products, and perhaps final reaction products collect in a collection area (60) having an upper surface defined by an upper surface of the release chamber (14).

Abstract: High purity tantalum metals and alloys containing the same are described. The tantalum metal preferably has a purity of at least 99.995% and more preferably at least 99.999%. In addition, tantalum metal and alloys thereof are described, which either have a grain size of about 50 microns or less, or a texture in which a (100) intensity within any 5% increment of thickness is less than about 15 random, or an incremental log ratio of (111):(100) intensity of greater than about −4.0, or any combination of these properties. Also described are articles and components made from the tantalum metal which include, but are not limited to, sputtering targets, capacitor cans, resistive film layers, wire, and the like. Also disclosed is a process for making the high purity metal which includes the step of reacting a salt-containing tantalum with at least one compound capable of reducing this salt to tantalum powder and a second salt in a reaction container.

Abstract: High purity tantalum metals and alloys containing the same are described. The tantalum metal preferably has a purity of at least 99.995% and more preferably at least 99.999%. In addition, tantalum metal and alloys thereof are described, which either have a grain size of about 50 microns or less, or a texture in which a (100) intensity within any 5% increment of thickness is less than about 15 random, or an incremental log ratio of (111):(100) intensity of greater than about −4.0, or any combination of these properties. Also described are articles and components made from the tantalum metal which include, but are not limited to, sputtering targets, capacitor cans, resistive film layers, wire, and the like. Also disclosed is a process for making the high purity metal which includes the step of reacting a salt-containing tantalum with at least one compound capable of reducing this salt to tantalum powder and a second salt in a reaction container.

Abstract: Methods to at least partially reduce a niobium oxide are described wherein the process includes heat treating the niobium oxide in the presence of a getter material and in an atmosphere which permits the transfer of oxygen atoms from the niobium oxide to the getter material, and for a sufficient time and at a sufficient temperature to form an oxygen reduced niobium oxide. Niobium oxides and/or suboxides are also described as well as capacitors containing anodes made from the niobium oxides and suboxides.

Abstract: Methods to at least partially reduce a niobium oxide are described wherein the process includes heat treating the niobium oxide in the presence of a getter material and in an atmosphere which permits the transfer of oxygen atoms from the niobium oxide to the getter material, and for a sufficient time and at a sufficient temperature to form an oxygen reduced niobium oxide. Niobium oxides and/or suboxides are also described as well as capacitors containing anodes made from the niobium oxides and suboxides.

Abstract: A method for producing high-purity niobium involves refining crude niobium in an electrolyte comprising a melt of salts containing a complex niobium and potassium fluoride and an equimolar mixture of alkaline metal chlorides, the electrolyte further containing sodium fluoride in the amount of from 5 to 15 wt %, and subjecting the obtained cathode deposit to electron-beam melting in a vacuum free of oil vapors under a residual gas pressure of from 5*10−5 to 5*10−7 mm Hg, a melting rate of from 0.7 to 2 mm/min and a leakage into a melting chamber from 0.05 to 0.005 l·&mgr;m/s to produce an ingot of niobium. The method produces high-purity niobium having the total amount of impurities within the range of from 0.002 to 0.007 wt % which satisfies the requirements imposed on the materials used in microwave technology and microelectronics, with reduced losses of niobium in both of the refining stages and increased yield of high-purity niobium.

Abstract: The tantalum powder for capacitors of the present invention has a specific surface area SB as determined by the BET method of 1.3 m2/g or more, and an SB/SF ratio between the specific surface area SB as determined by the BET method and the specific surface area SF determined by the FSS method of 4 to 10. This tantalum powder not only has a large specific surface area SB, but also has suitable cohesive strength and uniform porosity.

Abstract: High purity tantalum metals and alloys containing the same are described. The tantalum metal preferably has a purity of at least 99.995 % and more preferably at least 99.999%. In addition, tantalum metal and alloys thereof are described, which either have a grain size of about 50 microns or less, or a texture in which a (100) intensity within any 5% increment of thickness is less than about 15 random, or an incremental log ratio of (111):(100) intensity of greater than about −4.0, or any combination of these properties. Also described are articles and components made from the tantalum metal which include, but are not limited to, sputtering targets, capacitor cans, resistive film layers, wire, and the like. Also disclosed is a process for making the high purity metal which includes the step of reacting a salt-containing tantalum with at least one compound capable of reducing this salt to tantalum powder and a second salt in a reaction container.

Abstract: A process for recovering and purifying vanadium found in petroleum coke is disclosed. Coke containing V and sulfur is charged to a molten metal bath and dissolved to form a molten metal bath with dissolved carbon, dissolved V metal and dissolved sulfur. At least a majority of the dissolved sulfur is released as H2S by maintaining reducing conditions in the bed, by maintaining a high concentration of dissolved carbon or addition of steam or hydrogen rich hydrocarbon such as methane or some combination of these approaches.

Abstract: In a process for dechroming, and/or depleting the MgO content of, steel slags, oxygen is introduced into the liquid steel slag to an extent sufficient for converting iron quantitatively to iron oxide and at least 5% by weight of the iron oxide contained in the slag to iron-III-oxide. The oxidized slag obtained solidifies and is disintegrated, whereupon the paramagnetic portions formed are magnetically isolated and separated from the dechromed slag.

Abstract: A continuous process for recovering vanadium values from petroleum coke is disclosed. A vanadium containing coke is charged to a molten metal bath to which oxygen containing gas is added in an amount sufficient to heat balance the process and produce off gas. The carbon in the coke dissolves in the molten metal bath as does the vanadium content of the coke. A majority, and preferably all, of the net addition of vanadium to the process is removed in the form of “dust” from the molten metal bath.

Abstract: The present invention discloses a tantalum powder for capacitors and a method for making said tantalum powder wherein agglomerated tantalum powder is produced by means of thermal agglomeration of starting tantalum powders in the presence of hydrogen.

Abstract: A process for recovering and purifying vanadium found in petroleum coke is disclosed. Coke containing V and other metals such as Ni is charged to a molten metal bath and dissolved to form a molten metal bath with dissolved carbon, dissolved V metal and dissolved Ni. Oxygen containing gas is added in an amount sufficient to heat balance the process and produce off gas. At least periodically the conditions in the bed are made more severely oxidizing so that a portion of the molten vanadium metal is oxidized to form slag. Oxidation is limited so that a majority of the Ni dissolved in the bath remains as dissolved elemental Ni metal. Oxidized vanadium species are continuously or intermittently withdrawn from the slag layer, by dust formation or by tapping the slag layer.

Abstract: A process for the recovery of vanadium from a petroleum coke or heavy hydrocarbon feed comprising dissolving the feed in a molten metal bath to which oxygen containing gas is added to maintain heat balance and bum off carbon. Preferably the feed is added via a high pressure nozzle as a coke/steam mixture discharged down into a molten metal bath. Preferably the net gas make from the molten metal reactor is quenched and/or cooled to permit dust recovery, with recycle of dust to the molten metal reactor. An iron/vanadium product is withdrawn from the molten metal reactor as a product.

Abstract: Valve metal articles such as wire, sheet or powder having a second metal, preferably in a peripheral margin, prepared by coating the valve metal with a salt solution of the metal additive and heat treating in the presence of an oxygen getter to remove the oxygen from the valve metal and the anion of the metal salt to form the metal additive. For tantalum wire a preferred second metal is nickel. A preferred oxygen getter is magnesium. Nickel-containing tantalum wire is useful for enhance bonding to sintered pressed tantalum powder pellets in the production of electrolytic capacitors.

Abstract: This invention provides improved production, continuous or batch, especially of metals which have been produced by versions of the Kroll and Ames processses. This list includes titanium, zirconium, hafnium, vanadium, niobium, tantalum, rhenium, molybdenum, tungsten, and uranium. It also offers a process for growing particular shapes of metallic crystals, e.g., needlelike. This invention is intended to be less expensive to operate and to provide a superior product than from Kroll batch processing, as often used: For the continuous metal production, circulating molten salt supports two principal reaction stages, which together allow continuous metal production: Titanium powder production with one possible set of reactants may be used as an example for the group of metals listed: In Stage 1 a pumped solution of titanium ions (Ti++) dissolved in molten salt (e.g., MgCl2—KCl) flows onto, then down beside, molten magnesium that floats on molten salt below.

Abstract: Tantalum scrap of high oxygen content is recovered and processed to metallurgical grade tantalum by fine participation. Blending with carbon or other appropriate solid reducing agent, melting in a plasma furnace (20) at about tantalum melt temperature while suppressing partial pressure of tantalum oxide gas to minimize tantalum loss of the process.

Abstract: Besides a synthesis gas, a metallurgical raw material is to be produced from an oil containing heavy metals. To do this, the oil is partially oxidized and the heavy metal-containing soot is separated and burnt and the heavy metals thus occurring as ash can be taken to further processing, e.g. washing from the synthesis gas produced, using an aqueous washing solution.

Abstract: The process comprises the reduction of niobium and/or tantalum oxides by means of alkaline earth metals and/or rare earth metals, wherein the first reduction stage is carried out as far as an average composition corresponding to (Nb, Ta)O.sub.x where x=0.5 to 1.5 and before the second stage the reduction product from the first stage is freed from alkaline earth oxides and/or rare earth metal oxides which are formed (and optionally from excess alkaline earth metal and/or rare earth metal) by washing with mineral acids.

Abstract: A process for sizing (i.e., comminuting) a tantalum powder including agglomerates of smaller particles, which process yields a tantalum powder having an as-comminuted agglomerate size distribution with the product of the Volume Mean Diameter, MV (in microns as measured by light scattering techniques such as Microtrac analysis), times specific surface area, BET (m.sup.2 /g), being less than about 25. These powders after sizing typically have ratios of Scott Bulk Density : BET Surface Area in the range from about 20 to about 35. Also provided are powders having a substantially unimodal and narrow agglomerate size distribution in all stages of production, namely after sizing (i.e., deagglomeration by comminution), thermal agglomeration (i.e., heat treatment), and deoxidation. These resultant powders have high surface area and good flowability properties and, upon sintering, exhibit controlled shrinkage with high porosity.

Abstract: In a process for the production of hydraulic binders, crude steel and/or alloys, such as, e.g., FeCr or FeV, from basic steel slags containing chromium and/or vanadium, the liquid steel slag is mixed with an additive selected from the group consisting of blast furnace slag, electric arc furnace slag, dusts from steel production, metallic waste substances or refuse incineration residues and/or with acid additives for lowering the viscosity, whereupon steel is sedimented out of the liquid slag and the remaining slag in a first reduction stage is reduced to metallic iron having an iron oxide content of below 5 wt. % and above 1 wt. %, whereupon the remaining slag melt in a second reduction stage having a higher reduction potential as compared to the first reduction stage is further reduced to metallic Cr or V or ferroalloys thereof and the hydraulically active slag is separated.

Abstract: A method of separating vanadium from waste ash including generating a high temperature thermal plasma; contacting the waste ash with the high temperature thermal plasma in the presence of oxygen, thereby forming a layer of iron from iron and iron components contained within the waste ash and a layer of slag on top of the iron layer; causing vanadium contained within the waste ash to collect at an upper surface of the layer of iron and then react with the oxygen to form vanadium oxides and combine with the layer of slag; removing most of, but not all of, the layer of iron; stirring the layer of slag without addition of more of the oxygen; adding aluminum and carbon to the layer of slag; reducing or terminating power supplied to generate the high temperature thermal plasma; causing the aluminum to replace the vanadium in the vanadium oxides and causing the carbon to remove oxygen from iron oxides in the remaining portion of the layer of iron, whereby vanadium and iron combine to form a ferro-vanadium alloy.

Abstract: Vanadium-aluminum master alloys with small amounts of refractory metals such as ruthenium, are made substantially free of refractory inclusions and with a substantially homogeneous microstructure by reacting vanadium oxides with excess aluminum through an aluminothermic reduction reaction in the presence of the refractory to yield the desired master alloy. A preferred homogeneous vanadium-aluminum-ruthenium alloy without inclusions contains from about 59 to 70% of vanadium, about 29 to 40% of aluminum, and about 1 to 10% of ruthenium, all based on the weight of the alloy. The substantially homogeneous and inclusion-free master alloy is then used to produce titanium base alloys of higher quality, such as 4% vanadium and 6% aluminum titanium base alloys containing small amounts of refractory metals, usually containing from about 0.1 to 1.0% of ruthenium.