Patent ID: 8673051
Filing Date: 2014-03-18
Classification: B22F,C23C,H01G

Abstract:
1. A process for the production of metal powder comprising the steps of: (a) reducing a mixture of at least one metal halide by molten metal reduction of the liquid phase of the metal halide in a reductant selected from an alkali or alkaline earth metal, wherein the metal halide is present as a stoichiometric excess of the molten reductant, thereby forming reaction products comprising molten metal, metal halide, and free metallic reductant; (b) separating the reaction products formed in step (a); and (c) forming a metal powder from a reaction product in step (b); wherein the at least one metal halide mixture comprises a mixture of metal chlorides and the reductant is metallic sodium; and wherein the process is conducted as a one-pass operation in which the molten metal is reacted with a liquid metal halide and the solids are recovered with only the molten metal being intentionally recirculated.