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Titanium is manufactured through a process called the Kroll Process. Here's a simplified version of the process:
1. The process starts with the extraction of titanium ore, mainly consisting of rutile and ilmenite, from the earth.
2. The titanium ore is then shipped to a manufacturing facility where it's converted into titanium tetrachloride through a process involving chlorine and coke at very high temperature.
3. This titanium tetrachloride is a volatile liquid, and it is purified with the use of fractional distillation.
4. Post purification, titanium tetrachloride is reduced to metallic titanium by use of magnesium in a heated, closed system.
5. The initial result of this process is a mixture of porous sponge-like material containing titanium, magnesium chloride, and other remnants.
6. This sponge is then chemically processed to get rid of any magnesium chloride and other remnants.
7. The clean sponge is then melted into bars called 'electrodes' using vacuum arc remelting or other similar processes.
8. The electrodes are then melted again (often multiple times) into titanium ingots.
9. These ingots are later turned into slabs, plates, billets, rods and other forms as per the need of industries.
Please note, the manufacturing process of titanium can involve various other steps based on the purity level needed and the manufacturing practices involved in the specific facility.
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