Production of fine tantalum powder by preform reduction process using Mg–Ag alloy reductant

A preform reduction process (PRP) using Mg–Ag alloy reductant based on the magnesiothermic reduction of oxide by Mg vapor with reduced vapor pressure was investigated in order to produce fine, high-purity tantalum powder for electronic devices. A solid feed preform was fabricated by calcinating a slurry comprising a mixture of tantalum oxide powder, flux (e.g., CaCl2), and binder. It was then placed on a stainless steel mesh suspended above the Mg–Ag alloy reductant and reduced by Mg vapor generated from the alloy while heating at a constant temperature of 1273 K. Tantalum powder with a purity of more than 99 mass% and a narrow particle size distribution (D10 = 0.2 μm; D50 = 0.4 μm; D90 = 0.9 μm) was successfully obtained under a specific condition. The nickel contamination of the powder from stainless steel is lowered by using the alloy reductant in comparison with using pure Mg reductant. It was found that the particle size of the powder decreased with the vapor pressure of Mg; therefore, it can be controlled by controlling the vapor pressure of Mg.