The feasibility of producing titanium metal from titanium tetrachloride in a thermal plasma under equilibrium and adiabatic expansion conditions has been theoretically investigated. Free energy minimisation and adiabatic expansion calculations to simulate a nozzle expansion were used to study the practicality of production. The crucial requirements for the production of titanium powder from TiCl4 and H-2 appear to be rapid quenching of the plasma gas at high temperature (e.g., 3700 K) and appropriate reactant concentrations. Quenching of the plasma gas and production of titanium powder can be achieved by adiabatic expansion through a nozzle. Preliminary experimental data indicate that titanium powder of approximately 5 nm in size can be produced in an argon plasma using a nozzle expansion approach.