Benefits

The FFC Process has benefits over the conventional technologies, such as Kroll and Hunter, in two primary categories:

Capital Cost & Intensity

The FFC Process requires a relatively simple molten salt management system and a well engineered electrochemical cell. Within the cell is a sealed crucible that holds the salt and a cathode/anode configuration.

By comparison, the Kroll process involves the introduction of titanium tetrachloride to liquid magnesium to produce titanium sponge and magnesium chloride. Both the tetrachloride and magnesium are extremely hazardous reagants that require extensive health and safety protocols as well as complex equipment to handle safely. As part of the process, the magnesium chloride is electrochemically recycled to produce chlorine gas and magnesium. Chlorine is also a hazardous reagent.

Metalysis estimates that the capital cost of a FFC plant to be less than 25% of a Kroll plant (typically $300m - $500m.)

Operating Costs

TThe FFC Process uses one reagent, carbon, which is used as the anode in the cell. The carbon reacts with the oxygen ions to form carbon dioxide during the process. Despite these carbon emissions, a joint 2004 Carbon Trust and Metalysis report concluded that the FFC process had approximately 50% of the carbon footprint of conventional technologies.

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  Argon gas

  Used to cool the product and prevent re-oxidation. Argon is found in the atmosphere and will be recycled.

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  Electricity

  The process typically operates at 3 volts (the power of an ordinary torch battery), although the current passed depends on the amount of oxide that is being reduced.

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  Water

  De-ionised (distilled) water is used to wash excess calcium chloride from the reduced product. This will be filtered and recycled.

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  Calcium Chloride

  Calcium chloride is used as the electrolyte to convey the oxygen ion across to the anode. Calcium chloride is spread on the roads in the UK during winter and, despite being no more toxic than table salt (NaCl) and not regarded as a pollutant, will in any event be recycled.

The lack of any expensive reagents and relative simplicity of handling carbon dioxide results in operating costs that are considerably lower than the Kroll or Hunter processes. For titanium, this equates to a process cost saving of between 25% and 50% of conventional costs.

The combination of lower capital and operating costs, promises to open up new markets for titanium that could see the ninth most common element in the earth’s crust appear in everyday use in the automobile, chemical, medical device, sport and leisure equipment sectors, as well in its traditional high-value applications in the aerospace and defence industries.