Stage | Process Step | Description | PTC Industries Involvement |
|---|
1 | Ore Mining & Concentration | Titanium-bearing minerals (like ilmenite or rutile) are mined and processed to extract titanium dioxide (TiO₂). | Not Involved |
2 | Chlorination | Purified TiO₂ is treated with chlorine gas and carbon at high temperatures to produce titanium tetrachloride (TiCl₄). | Planned (Future Sponge Plant) |
3 | Purification | Crude TiCl₄ is purified through fractional distillation to remove impurities. | Planned (Future Sponge Plant) |
4 | Reduction (Kroll Process) | Purified TiCl₄ is reduced using molten magnesium to produce porous "titanium sponge." | Planned (Future Sponge Plant) |
5 | Sponge Crushing & Pressing | Titanium sponge is crushed and pressed into compact forms (electrodes). | Planned (Future Sponge Plant) |
6 | Electrode Preparation | Multiple pressed sponge electrodes are welded together to form a consumable electrode. | Current Capability |
7 | Vacuum Arc Remelting (VAR) – Primary Melt | Sponge electrode is melted in a vacuum to form the first titanium alloy ingot. | Current Capability |
8 | Vacuum Arc Remelting (VAR) – Secondary Melt | Primary ingot is re-melted to ensure chemical uniformity and purity, producing the final ingot. | Current Capability |
9 | Quality Assurance (Ingot) | Solidified ingot is inspected; defective sections are cropped to ensure material integrity. | Current Capability |
10 | Forging / Billet Conversion | Ingot is heated and forged to break down cast structure and create a semi-finished billet. | Future Capability (Expansion) |
11 | Rolling & Shaping | Billet is processed through rolling mills to produce bars, rods, or plates. | Future Capability (Expansion) |
12 | Cutting to Size | Mill products are cut to required dimensions for the next manufacturing stage. | Future Capability (Expansion) |
13 | Precision Investment Casting | Molten titanium is poured into a ceramic mold to create a near-net-shape casting. | Current Capability |
14 | Hot Isostatic Pressing (HIP) | Casting is subjected to high temperature and pressure to eliminate internal porosity. | Current Capability |
15 | Precision Machining | Casting is CNC-machined to achieve final, precise dimensions and surface finishes. | Current Capability |
16 | Surface Coating & Treatment | Special coatings (e.g., thermal barrier) or chemical treatments are applied to enhance performance. | Current Capability |
17 | Final Quality Assurance & Inspection | Finished part undergoes rigorous non-destructive testing (NDT) to meet all specifications. | Current Capability |