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Bhp — BHP Billiton — Titanium 2005 – 21st Annual ITA Conference

13 slides from Bhp's conference presentation, Sep 27, 2005

  1. Slide 1: Polar Titanium – Development of the BHP Billiton Titanium Metal Production Process

    Polar™ Titanium – Development of the BHP Billiton Titanium Metal Production Process G.D. Rigby, I.P. Ratchev, R.I. Olivares, K. Mukunthan, S.A. Bliznyukov, and A.A. Shook Titanium 2005 – Emerging Technologies session 21st Annual ITA Conference 25-27 September 2005, Scottsdale, AZ, USA

  2. Slide 2: The Polar Titanium process is based on reduction of TiO2 to Ti using molten salt electrochemistry

    The Polar™ Titanium process is based on reduction of TiO2 to Ti using molten salt electrochemistry Cathodic reactions CaO(in salt) + 2e- = CaMet (in salt) + O2- e- _ + Carbon TiO2 + 2Ca(in salt) = Ti + 2CaO(in salt) anode Anodic reactions O2- + C(anode) = CO(gas) + 2e- Cathode Molten salt 2O2- + C(a

  3. Slide 3: Polar Titanium - Project history

    Polar™ Titanium - Project history 2001 - 2002 2003 - 2004 2004 - 2005 Gram-scale - fundamentals Design, construction, commissioning kg-scale operation 2002 2003 2004 2005 2001 2006 Fundamental program • Elucidated the key reaction mechanisms and provided an IP portfolio base. • Provided key understa

  4. Slide 4: Attributes of the experimental facilities – main reactor

    Attributes of the experimental facilities – main reactor REACTORS • Containment of up to 1 t of molten salt (CaCl2). • CaCl2 preheating and melting plant for reactor startup (patented). • Molten CaCl2 salt temperature up to 150°C of salt superheat (i.e. to 930°C in-salt temperature). • Variable redu

  5. Slide 5: Titanium produced in recent reactor trials for a range of feed types

    Titanium produced in recent reactor trials for a range of feed types 5.0 14 12 4.0 Titanium produced (kg) 10 Cumulative Titanium (kg) 3.0 8 6 2.0 4 1.0 2 0.0 0 March 2005 August 2005 Titanium 2005 – 21st Annual ITA Conference, Scottsdale, AZ, USA – 25-27 September 2005 © BHP Billiton Innovation Pty

  6. Slide 6: Oxygen content in reduced titanium during experimental program

    Oxygen content in reduced titanium during experimental program 1.0 5.0 0.8 4.0 Titanium produced (kg) 0.6 3.0 Oxygen (%) 0.4 2.0 0.2 1.0 0.0 0.0 March 2005 August 2005 Titanium 2005 – 21st Annual ITA Conference, Scottsdale, AZ, USA – 25-27 September 2005 © BHP Billiton Innovation Pty Ltd – September

  7. Slide 7: Carbon content in reduced titanium during experimental program

    Carbon content in reduced titanium during experimental program 0.10 5.0 0.08 4.0 Titanium produced (kg) 0.06 3.0 Carbon (%) 0.04 2.0 0.02 1.0 0.00 0.0 March 2005 August 2005 Titanium 2005 – 21st Annual ITA Conference, Scottsdale, AZ, USA – 25-27 September 2005 © BHP Billiton Innovation Pty Ltd – Sep

  8. Slide 8: A range of TiO2 feed morphologies have been tested

    A range of TiO2 feed morphologies have been tested Micrographs show fracture surfaces of TiO2 feed forms. Increasing sintering temperature Increasing BET surface area (m2/g) Increasing reactivity Increasing physical integrity Titanium 2005 – 21st Annual ITA Conference, Scottsdale, AZ, USA – 25-27 Se

  9. Slide 9: Final titanium metal product - morphology changes throughout the reduction process

    Final titanium metal product - morphology changes throughout the reduction process Feed stock (TiO2) CaTiO3 • The morphology of the final titanium develops to the final form as the oxygen content is progressively reduced. TiO Ti metal (high O) Ti metal (low O) Scale 10 μm Titanium 2005 – 21st Annual

  10. Slide 10: Typical product chemistry

    Typical product chemistry Product analysis comments • As reduction reactions proceed, the feed form progressively attains final product specifications, moving through a series of transitions to produce Ti: TiO2 ⇒Ti4O7 ⇒ Ti3O5 ⇒ Ti2O3 ⇒ CaxTiyOz ⇒ TiO ⇒ Ti metal (0 to 15% O) 20 100 • Potential for a

  11. Slide 11: Titanium metal produced in the Polar reactor has been amenable to milling to powder

    Titanium metal produced in the Polar™ reactor has been amenable to milling to powder 0.5 -1.0 mm 0.25-0.50 mm • Milling of Ti product accomplished using standard hammer and disc mill equipment with inert gas shroud. • Milled shape is encouraging for all size distributions. • Pre-milling morphology o

  12. Slide 12: Process and commercial development

    Process and commercial development • BHP Billiton have committed significant resources to the experimental program for Polar™ Titanium development. • There has been promising experimental process development, from gram to kilogram scale at BHP Billiton’s Newcastle Technology Centre. • A program of p

  13. Slide 13: Titanium 2005 – 21 st Annual ITA Conference, Scottsdale, AZ, USA – 25-27 September

    Titanium 2005 – 21st Annual ITA Conference, Scottsdale, AZ, USA – 25-27 September 2005 © BHP Billiton Innovation Pty Ltd – September 2005

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