Process and apparatus for producing powder particles by atomization of a feed material in the form of an elongated member

An apparatus for producing powder particles by plasma atomization of a feed material, comprising:

• a) a plasma atomization section including an enclosure in which plasma is generated, the enclosure including:
• i. an upper portion for receiving the feed material;
• ii. a lower portion having a nozzle, the nozzle comprising a nozzle body having an inlet and an outlet, the nozzle body defining a passageway extending between the inlet and the outlet, the passageway being configured for conveying a stream of droplets produced by progressive break down of the feed material by the plasma generated in the enclosure, the passageway comprising in a direction from the inlet of the nozzle to the outlet:
• a. a first section of decreasing cross-sectional width;
• b. a second section of increasing cross-sectional width;
• and
• c. an intermediate section between the first section and the second section;
• the nozzle body including an inert gas inlet configured to introduce an inert gas to the stream of droplets;
• and
• b) a cooling section including a cooling chamber, wherein the enclosure is in communication with the cooling chamber via the outlet of the nozzle and the cooling chamber is configured to receive the droplets and permit solidification of the droplets into powder particles.