Electro-Reduction of Ilmenite to FexTi Alloys in Molten CaCl2

This paper reports the preparation of FexTi alloys from natural ilmenite by electro-reduction in molten CaCl2. The electro-reduction experiment was carried out at 1000 °C and potential of 3.8 V, and an inert solid oxide oxygen-ion-conducting membrane (SOM) anode system was used to control the electrochemical experiment. The phase composition and morphology of the final product were investigated. The reaction mechanism involved in the electro-reduction process is discussed based on our experimental results and thermodynamic analysis. It is suggested that FexTi alloys powder with different Fe contents (FexTi, 0 ≤ x ≤ 2) and particle sizes can be obtained by controlling electrolysis conditions strictly. The result implies that the SOM process is a promising green method for the preparation of ferrotitanium alloys direct from natural ilmenite.