Low-temperature synthesis of zirconium metal using ZrCl4–2Mg reactive mixtures

In this paper, we describe an attractive and rapid process for preparing zirconium metal (sponge and powder) by reacting zirconium tetrachloride with magnesium powder. The process was carried out in the combustion synthesis (shortly CS) mode using a ZrCl4–2Mg exothermic mixture, which provided a temperature of 1000–1100 °C and a final product consisting of MgCl2 and Zr sponge. The separation of Zr sponge from the reaction product was accomplished by dissolving MgCl2 into warm acidified water. The average size of the Zr sponge particles ranged from about 1 mm to about 10 mm. Micrometer-sized (from 10 to 300 μm) Zr powders were also obtained after mechanical processing of sponge. The characteristics of the Zr metal were established by X-ray diffraction, scanning electron microscopy, and inductively coupled plasma spectroscopy techniques.

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► A combustion process to produce zirconium metal using ZrCl4 and Mg was proposed.
► The entire process was finished within tens of seconds.
► Acid leaching was performed and phase-pure Zr sponge was obtained.
► The purity of the Zr sponge was found to be better than 99%.