Methods using high surface area per volume reactive particulate

A method of processing finely divided reactive particulates (RParticulate) and forming a product comprising:

• providing a solid composite material comprising
• (a) a protective matrix,
• (b) finely divided reactive particulates (RParticulate) dispersed in the protective matrix, and
• (c) at least one of (i) one or more metal compounds (MPCR) in one or more oxidation states, and (ii) a reductant (R),
• with the finely divided reactive particulates (RParticulate) having a particle size of up to 1 micron and the surface area to volume ratio of said finely divided reactive particulates (RParticulate) in said protective matrix being greater than 6 m2/mL,
• with the finely divided reactive particulates (RParticulate) comprising a metal or a metalloid selected from the group consisting of titanium, aluminium, vanadium, chromium, niobium, molybdenum, zirconium, silicon, boron, tin, hafnium, yttrium, iron, copper, nickel, bismuth, manganese, palladium, tungsten, cadmium, zinc, silver, cobalt, tantalum, scandium, ruthenium and the rare earths or a combination of any two or more thereof, and
• with the protective matrix comprising a metal halide (MRX) selected from the group consisting of MgCl2, NaCl, KCl, LiCl, BaCl2, CaCl2, BeCl2, AlCl3 and any combination thereof;
• at least partially exposing said finely divided reactive particulates (RParticulate) by subjecting said composite material to vacuum distillation, resulting in volatilisation of said matrix;
• and
• forming said product.