This research focused on obtaining titanium powder (2.9 wt% O) through magnesiothermic reduction of TiO2. Key components of the study included: (1) thermochemical simulations to identify optimal process variables, (2) designing three reactor types to facilitate solid-liquid and solid-gas reactions, (3) conducting 89 metallothermic reduction experiments to assess the effects of time, temperature, Mg/TiO2 molar ratio, TiO2 size, and magnesium shape, (4) performing 14 leaching processes with various acid mixtures to purify solid titanium by dissolving Mg, MgO, Ni, Fe, magnesium titanates, and titanium oxides, and (5) outlining the magnesiothermic pathway. The findings revealed that (1) high titanium metal yields were achieved with a solid-gas reaction in a rotating setup, (2) temperature control is crucial, as reoxidation of Ti occurs above 1400°C, (3) reactor design significantly impacts titanium powder yield, (4) the optimal configuration was a sealed rotary tube reactor with separate compartments for magnesium and TiO2, and (5) a mixture of 8% HCl and 3% HNO3 at 20°C for 24 hours maximized sub-product dissolution while minimizing titanium loss. Irregular and semispherical powder particles sized between 5 to 20 µm were successfully produced.
