Low temperature method of forming materials using one or more metal reactants and a halogen-containing reactant to form one or more reactive intermediates

Claim 1

A low temperature process for forming a powder comprising one or more metals compounds which comprises: (a) reacting one or more metal reactants selected from the class consisting of Al, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W, and Si with a halide-containing reactant selected from the class consisting of X 2 , HX, MX a , or MX.sub.(a-b H b where X is F, Cl, Br, or I; M is one or more metals selected from the class consisting of said metal reactants and Pb; a is the maximum oxidation state or valence of said one or more metals M; and b has a value of from 1 to a-1, in a first reaction zone in a reactor comprising a fluidized bed to form one or more reactive intermediates capable of forming a powder; and (b) contacting, in a second reaction zone spaced from said first reaction zone in said reactor, said one or more reactive intermediates formed in said first reaction zone with a third reactant, which third reactant is introduced into said reactor at said second zone, and which is different from said halide-containing reactant, and which is selected from the class consisting of a carbon-containing reactant, an oxygen-containing reactant, a nitrogen-containing reactant, and mixtures thereof to form said powder comprising respectively, one or more metal carbides, metal oxides, metal nitrides, or a mixture thereof, of said one or more metal reactants.