The value chain of Titanium powders is a long path
from product design to end-user.
Raw material supply is critical because it is mainly coming from outside the EU zone, and production processes are extremely energy dependent with a high level of carbon footprint.
The REPTiS partner Velta invented and patented the Velta Ti Process that already gives advantages over current processes in the following areas:
- Avoidance of solid and liquid waste generation
- Significant reduction of the carbon footprint
- Improved particle size control of finished powders
- Improved homogeneity of alloying additives distribution in alloys
- Significant reduction in the cost of finished products
Extraction
The source of Titanium in REPTiS is a titanium-iron oxide mineral with the idealized formula FeTiO3, Ilmenite, whose mining and extraction is not common in Europe. The strategic Ukrainian partner VELTA is running open pit mining activities in Ukraine for this mineral. Their mining processes will be further improved in terms of sustainability and safety to lower the environmental impacts and risks in parallel with the EU Zero Pollution Action Plan and Materials 2030 Roadmap policies. The potentials for other CRM in the extracted minerals will also be investigated.
Processing of Ti and by-products
The patented Velta Ti process [1] uses the Ilmenite mineral to produce non-spherical and spherical Ti alloy powders with extremely low oxygen content, as well as many by-products that can be valorised. It consists of several steps as visible in the chart:
- Decomposition of Ilmenite concentrate
- Hydrolysis of titanium oxychloride solutions
- Washing, filtration of titanium oxides/hydroxides
- I-synrutile roasting and grinding
- Formation and calcining
- 1st stage: Ti reduction via Mg
- Washing, filtration, drying and classification
- 2nd stage of Ti reduction by Ca
- Spheroidisation (where needed)
By-products: Calcium oxide & carbon dioxide; Calcium metal; Veltilit BF; Ferric hydroxide; Black, yellow and red iron oxide pigments; Regenerated hydrochloric acid; Ammonium sulphate; Sulfuric acid; Magnesium hydroxide.
[1] Brodskyy et al, United States Patent; Patent No 011440096B2; 13 September 2022
Demonstration and assessment
Case studies will be used to demonstrate the performance and capability of the new processes, and to show that the project technology achieves the targeted TRL7.
Four case studies are selected from different sectors to cover the entire titanium industry properly. These cases are from: medical, aerospace, and consumer goods.
The functionality assessment will be done with the relevant measurement and testing devices, and in-house evaluation tests and application tests will be performed by related industrial partners. All four cases will be investigated individually in detail in terms of economic feasibility, CO2 footprint, energy, and water consumption through an LCA and LCC study.
A Product Environmental Footprint (PEF) report will be produced, to document the environmental performance.
