Abstract
The Kroll process for magnesium reduction of titanium tetrachloride is used for mass production of titanium sponge. The present study was conducted in a lab scale reactor to develop a better understanding of the mechanism of titanium sponge formation in the Kroll reactor with respect to reaction degrees and the feeding rate of $TiCl_4$. The $MgCl_2$ produced during the initial stage of the reaction was not sunk into the molten magnesium, but covered the surface of the molten magnesium. As a result, subsequently fed $TiCl_4$ reacted with Mg exposed on the edge of molten $MgCl_2$ in the crucible. Therefore, titanium sponge grew toward the center of the crucible from the edge. The temperature of the molten magnesium increased remarkably with the increasing feeding rate of $TiCl_4$. Consequently, fed $TiCl_4$ reacted at the upper side of the crucible with evaporated Mg, and produced titanium on the upper surface of the crucible wall, which increased considerably with the feeding rate of $TiCl_4$.