In this study, the deoxidation process for off-grade titanium (Ti) sponge using magnesium (Mg) metal with a wire mesh strainer type of crucible was developed. Ti hydride (TiH2) feedstock, which was prepared by hydrogenating off-grade Ti sponge, was deoxidized using Mg in a molten magnesium chloride-potassium chloride salt at 933 K under an argon and 20% hydrogen (H2) mixed gas atmosphere. After deoxidation, the residual Mg-containing salt was separated in situ from the crucible to investigate the feasibility of minimizing salt loss during the leaching and production of pure TiH2. The results showed that the presence of residual Mg-containing salt inside the crucible strongly influenced whether a mixture of Ti and TiH2 or pure TiH2 was produced. When the salt was not sufficiently separated, a mixture of Ti and TiH2 was obtained and its oxygen (O) concentration was 0.121 mass% under certain conditions. Meanwhile, pure TiH2 was obtained by increasing the H2 gas flow rate during deoxidation. Therefore, these results demonstrate that the decrease of O concentration to below 0.180 mass% and the minimal loss of the salt are feasible.
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