A direct electrochemical route from ilmenite to hydrogen-storage ferrotitanium alloys

An unrecognised but predictable need for a hydrogen-supported society is tens or even hundreds of million tonnes of hydrogen-storage materials, and thus challenges existing technologies in terms of resource and economical realities. Ilmenite is an abundant mineral, and ferrotitanium alloys are among the earliest known hydrogen-storage materials. At present, industrial production of ferrotitanium alloys goes through separate extraction of individual metals, followed by a multistep arc-melting process. In particular, the extraction of titanium from ilmenite is highly energy intensive and tedious, accounting for titanium's high market price and restricted uses. This article reports the electrochemical synthesis of various ferrotitanium alloy powders directly from solid ilmenite in molten calcium chloride. More importantly, it demonstrates, for the first time, that such produced alloy powders can be used without further treatment for hydrogen storage and perform comparably with or better than similar products by means of other methods, but cost just a fraction.