Metallic titanium is commonly produced by the carbon-dioxide-emitting
Kroll process. The modern shift to sustainable technology has generated
global interest in green processes. A carbon-free route for Ti manufacturing
via the fabrication of a copper–titanium alloy and its electrorefining
has been previously reported. This study focuses on the sustainability
of the Ti-production electrorefining process (using a CuTi-alloy anode
in LiF–NaF molten salt, with BaTiF6 addition, at
750 °C). BaTiF6, produced by a chemical reaction,
was used as a K-free alternative to K2TiF6.
The Ti-reduction mechanism and the anodic dissolution of Ti, CuTi,
and Cu were investigated by potential sweep methods. Selective anodic
dissolution of Ti, without Cu codissolution, occurred in a wide anodic
potential range (−0.6 to 0.9 V vs W). Moreover, the Cu matrix
remained on the anode, without sludge formation in the electrolyte,
eliminating Ti-deposit recontamination by the anode material. Energy
consumption and CO2 emissions were 1.66 times less than
those of the Kroll process. The Ti-deposit morphology (with temperature,
current density, and electrolysis-duration variation) was analyzed
by scanning electron microscopy (SEM). Additional experimentation
indicated that Ti can be electrochemically separated from Fe, confirming
that low-grade TiO2 raw materials and off-grade Ti sponge
could be used for the fabrication and processing of CuTi anodes.