ALFA MIMTECH strengthens its position as a leader in MIM technology through its participation in REPTiS, the ambitious European project that seeks to revolutionize the production of alloyed titanium powders through innovative and sustainable processes.
The REPTiS project (Responsible Extraction and Processing of Titanium and other Primary Raw Materials) has reached a crucial moment in its development, successfully completing its first year of activity and achieving one of its main objectives: Ukrainian ilmenite mineral samples have already been transferred to the processing stage, paving the way for the first manufacturing tests of titanium powder.
Key Highlights of the REPTiS Project Progress (Nov. 2025):
1. Major Milestone Achieved
- An optimized ilmenite concentrate has been produced and transferred to VELTA facilities for hydrometallurgical processing.
- In the coming months, titanium powders will begin to be produced and validated for all possible end users in the EU.
2. Innovation in the Velta Ti Process
- A revolutionary process operating at relatively low temperatures (~120°C), significantly reducing energy consumption.
- Closed-loop hydrochloric acid system that recovers approximately 50 % of the HCl used.
- Zero-waste production: all by-products are converted into valuable materials (iron oxide pigments, additives for blast furnace protection).
3. Focus on Sustainability
- Implementation of Life Cycle Assessments (LCA) and Life Cycle Costing (LCC) from the beginning of the project.
- Significant reduction in emissions, water consumption, and waste generation.
- Exploration of renewable energy and low-carbon technologies at all stages.
4. Four Strategic Demonstrators The titanium powders developed will be validated in real applications for the medical, aerospace, and consumer goods sectors.
5. Critical Raw Material Potential LPreliminary analysis of the Ukrainian ilmenite samples has revealed the presence of additional valuable elements: Nb, V, Hf, Sc, Y, La, Ce, Nd, and Th — opening new opportunities to develop a resilient supply chain within the EU.
The strategic context: Why REPTiS Is vital for Europe
Titanium is a critical material with strategic importance for Europe. Its properties are unmatched: high strength, low weight, excellent corrosion resistance, and biocompatibility. However, the environmental and economic costs of its production using conventional methods are equally significant.
The European Union has identified titanium as one of the essential critical raw materials for the green transition and strategic autonomy of the continent. Dependence on external supply chains and highly polluting traditional production methods (such as the Kroll process) have driven the search for more sustainable and secure alternatives.
REPTiS responds to this challenge by establishing a new supply chain of alloyed titanium powders from Ukraine — a strategic EU partner country — using the innovative Velta Ti process that eliminates many environmental and process issues associated with classical methods.
The Velta Ti Process Revolution: From Ilmenite to Titanium with Zero Waste
One of the most innovative aspects of the REPTiS project is the Velta Ti process, which represents a paradigm shift in metal titanium production.
How It Differs from the Traditional Process
The traditional Kroll process is based on titanium tetrachloride (TiCl₄), obtained through a complex chlorination of raw materials with high TiO₂ content (such as natural rutile, synthetic rutile, and titanium slag). This method has major drawbacks:
- High energy consumption
- Environmental risks due to the use of gaseous chlorine
- Carbothermal reactions at 800–1000 °C
- Generation of large amounts of hazardous waste
The Velta Ti ProcessiInnovation
The Velta Ti process uses titanium dioxide (TiO₂) obtained from ilmenite via decomposition with hydrochloric acid and hydrolysis of titanium oxychloride (TiOCl₂) This avoids the formation stage of titanium tetrachloride (TiCl₄) entirely, eliminating many environmental issues of the classical process.
Main Advantages
- Relatively low operating temperatures (~120 °C)
- Significant reduction in energy consumption
- Drastically lower emissions
- Closed-loop hydrochloric acid system: vaporized HCl from hydrolysis is fully captured, condensed, and returned to the initial stage
- Recovery of ~50 % of the HCl used
- Zero-waste production: all liquid and solid streams are recycled into valuable by-products
Valuable By-Products from the Velta Ti Process:
A revolutionary feature of the Velta Ti process is that it does not generate waste, but rather marketable by-products:
1. Iron Oxide Pigments After titanium separation, the ferrous chloride solution (FeCl₂) is processed into iron oxide pigments of various colors:
- Black pigments (magnetite, Fe₃O₄)
- Red pigments (hematite, α-Fe₂O₃)
- Yellow pigments (goethite, α-FeO(OH))
These pigments are high-purity, high-saturation products suitable for coatings, paints, plastics, paper, and construction materials.
2. Veltilit BF The insoluble sludge separated during processing becomes Veltilit BF — a titanium-containing additive used to protect blast furnace linings and extend their service life.
3. Calcium Chloride (CaCl₂) After pigment separation, the remaining solution — mainly calcium chloride — is not considered waste but is sent for further processing to derive other valuable products.
ALFA MIMTECH’s role in REPTiS: Industrial validation of titanium powders
ALFA MIMTECH plays a fundamental role in the REPTiS project as an end-user and industrial validator of the titanium powders developed through the Velta Ti process.
Watch case made using MIM technology
Metal Injection Molding (MIM): The Perfect Technology for REPTiS Powders
Metal Injection Molding combines the design freedom of plastic injection molding with the strength and durability of metals. This technology is ideal for leveraging the characteristics of fine titanium powders produced in REPTiS.
Within the REPTiS project, ALFA MIMTECH is responsible for producing the first demonstrator components using the titanium alloy powders developed in the project. This demonstrator is crucial for several reasons:
Technical Validation: It demonstrates that REPTiS powders meet the demanding requirements of industry.
High-Value Application: Parts with high mechanical requirements and tight tolerances represent one of the most demanding and profitable markets for titanium.
Proven Sustainability: MIM technology reduces raw material use and manufacturing time compared to other technologies, improving both cost and carbon footprint — especially for alloys that are difficult to machine, such as titanium.
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