Development of a bench-scale Kroll reactor: Experimental results and preliminary findings
The Kroll process remains the predominant method for large-scale titanium sponge production, involving the reduction of titanium tetrachloride (TiCl₄) with molten magnesium (Mg) under an argon (Ar) atmosphere at 1000-1100 K producing molten magnesium chloride (MgCl2) as a by-product. Despite its wid...
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| Language: | English |
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Elsevier
2025-09-01
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| Series: | Results in Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123025028671 |
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| author | T.A. Ferguson C. Reilly S.L. Cockcroft D․ M․ Maijer |
| author_facet | T.A. Ferguson C. Reilly S.L. Cockcroft D․ M․ Maijer |
| author_sort | T.A. Ferguson |
| collection | DOAJ |
| description | The Kroll process remains the predominant method for large-scale titanium sponge production, involving the reduction of titanium tetrachloride (TiCl₄) with molten magnesium (Mg) under an argon (Ar) atmosphere at 1000-1100 K producing molten magnesium chloride (MgCl2) as a by-product. Despite its widespread industrial use, the Kroll process has received limited attention in the scientific literature, with existing studies presenting limited process data with differing interpretations. This lack of comprehensive understanding has left key reaction mechanisms in the commercial process poorly defined. This study presents four experiments with varying process conditions using a benchtop-scale reactor with high-resolution temperature and pressure instrumentation. These process conditions include, with and without the initial presence of MgCl2, varying feed rates and different materials present in the reactor to assess their ability to serve as substrates for Ti-sponge formation. The experimental results showed that the Ti sponge can grow on any substrate material irrespective of electrical conductivity, indicating that electron transport through crucible walls is not essential for Ti growth. Instead, it was found that the capillary action of Mg through porous Ti sponge was the driving force behind the continuation of the reaction. Furthermore, the reaction rate changed throughout the TiCl4 feed, suggesting a changing surface area where the heterogenous reaction can occur. |
| format | Article |
| id | doaj-art-5224a30fe7ec40fa87100cc51fc9eb93 |
| institution | Kabale University |
| issn | 2590-1230 |
| language | English |
| publishDate | 2025-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Results in Engineering |
| spelling | doaj-art-5224a30fe7ec40fa87100cc51fc9eb932025-08-23T04:49:02ZengElsevierResults in Engineering2590-12302025-09-012710680310.1016/j.rineng.2025.106803Development of a bench-scale Kroll reactor: Experimental results and preliminary findingsT.A. Ferguson0C. Reilly1S.L. Cockcroft2D․ M․ Maijer3Corresponding author.; Department of Materials Engineering, University of British Columbia, 6350 Stores Rd, Vancouver, BC, CanadaDepartment of Materials Engineering, University of British Columbia, 6350 Stores Rd, Vancouver, BC, CanadaDepartment of Materials Engineering, University of British Columbia, 6350 Stores Rd, Vancouver, BC, CanadaDepartment of Materials Engineering, University of British Columbia, 6350 Stores Rd, Vancouver, BC, CanadaThe Kroll process remains the predominant method for large-scale titanium sponge production, involving the reduction of titanium tetrachloride (TiCl₄) with molten magnesium (Mg) under an argon (Ar) atmosphere at 1000-1100 K producing molten magnesium chloride (MgCl2) as a by-product. Despite its widespread industrial use, the Kroll process has received limited attention in the scientific literature, with existing studies presenting limited process data with differing interpretations. This lack of comprehensive understanding has left key reaction mechanisms in the commercial process poorly defined. This study presents four experiments with varying process conditions using a benchtop-scale reactor with high-resolution temperature and pressure instrumentation. These process conditions include, with and without the initial presence of MgCl2, varying feed rates and different materials present in the reactor to assess their ability to serve as substrates for Ti-sponge formation. The experimental results showed that the Ti sponge can grow on any substrate material irrespective of electrical conductivity, indicating that electron transport through crucible walls is not essential for Ti growth. Instead, it was found that the capillary action of Mg through porous Ti sponge was the driving force behind the continuation of the reaction. Furthermore, the reaction rate changed throughout the TiCl4 feed, suggesting a changing surface area where the heterogenous reaction can occur.http://www.sciencedirect.com/science/article/pii/S2590123025028671Kroll processMagnesiothermic reductionTitaniumMagnesiumTitanium tetrachloride |
| spellingShingle | T.A. Ferguson C. Reilly S.L. Cockcroft D․ M․ Maijer Development of a bench-scale Kroll reactor: Experimental results and preliminary findings Results in Engineering Kroll process Magnesiothermic reduction Titanium Magnesium Titanium tetrachloride |
| title | Development of a bench-scale Kroll reactor: Experimental results and preliminary findings |
| title_full | Development of a bench-scale Kroll reactor: Experimental results and preliminary findings |
| title_fullStr | Development of a bench-scale Kroll reactor: Experimental results and preliminary findings |
| title_full_unstemmed | Development of a bench-scale Kroll reactor: Experimental results and preliminary findings |
| title_short | Development of a bench-scale Kroll reactor: Experimental results and preliminary findings |
| title_sort | development of a bench scale kroll reactor experimental results and preliminary findings |
| topic | Kroll process Magnesiothermic reduction Titanium Magnesium Titanium tetrachloride |
| url | http://www.sciencedirect.com/science/article/pii/S2590123025028671 |
| work_keys_str_mv | AT taferguson developmentofabenchscalekrollreactorexperimentalresultsandpreliminaryfindings AT creilly developmentofabenchscalekrollreactorexperimentalresultsandpreliminaryfindings AT slcockcroft developmentofabenchscalekrollreactorexperimentalresultsandpreliminaryfindings AT dmmaijer developmentofabenchscalekrollreactorexperimentalresultsandpreliminaryfindings |