An apparatus for direct reduction of iron ore in a solid state including a pre-heating furnace for pre-heating iron ore fragments and biomass in briquettes of these materials to a temperature in the range of 400-900° C.; and a reduction assembly for briquettes from the pre-heating furnace. The reduction assembly includes a reaction chamber, a source of electromagnetic energy in the form of microwave energy, a wave guide for transferring microwave energy to the chamber for heating and reducing iron ore in briquettes from the pre-heating furnace, with biomass acting as a reductant, a source of an inert gas, pipework for supplying the inert gas to the chamber to maintain the chamber under anoxic conditions, and an outlet for discharging an offgas and any retained particulates that are generated in the chamber.

An apparatus for direct reduction of iron ore in a solid state including a pre-heating furnace for pre-heating iron ore fragments and biomass in briquettes of these materials to a temperature in the range of 400-900° C.; and a reduction assembly for briquettes from the pre-heating furnace. The reduction assembly includes a reaction chamber, a source of electromagnetic energy in the form of microwave energy, a wave guide for transferring microwave energy to the chamber for heating and reducing iron ore in briquettes from the pre-heating furnace, with biomass acting as a reductant, a source of an inert gas, pipework for supplying the inert gas to the chamber to maintain the chamber under anoxic conditions, and an outlet for discharging an offgas and any retained particulates that are generated in the chamber.

Processes for producing copper granules on a surface of a reducing metal. The process can include contacting the reducing metal with an aqueous solution comprising a copper(II) salt and a halide. The molar ratio of the halide to the copper(II) in the copper (II) salt can be at least about 3:1. The granular copper can be produced on a surface of the reducing metal, and is optionally removed from the surface of the reducing metal by shaking, washing, and/or brushing, and/or optionally with stirring and/or circulating of the aqeuous solution.

Processes for producing copper granules on a surface of a reducing metal. The process can include contacting the reducing metal with an aqueous solution comprising a copper(II) salt and a halide. The molar ratio of the halide to the copper(II) in the copper (II) salt can be at least about 3:1. The granular copper can be produced on a surface of the reducing metal, and is optionally removed from the surface of the reducing metal by shaking, washing, and/or brushing, and/or optionally with stirring and/or circulating of the aqeuous solution.

Methods and systems for producing are disclosed. A method for producing iron, for example, comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first anolyte has a different composition than the first catholyte; dissolving at least a portion of the iron-containing ore using an acid to form an acidic iron-salt solution having dissolved first Fe.sup.3+ ions; providing at least a portion of the acidic iron-salt solution to the first cathodic chamber; first electrochemically reducing said first Fe.sup.3+ ions in the first catholyte to form Fe.sup.2+ ions; transferring the formed Fe.sup.2+ ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe.sup.2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal.

Methods are proposed for extracting transition metal oxides from scrap batteries by dissolving the metal oxides in a glass-forming oxide melt, followed by electrolytic reduction of the transition metal onto the cathode of an electrolytic cell. Suitable glass-forming oxide melts include borate and pyrophosphate melts with added Na.sub.2O or NaF. The method is particularly suited to the recovery of cobalt, nickel, and manganese from scrap battery and electronic materials. A preferred recycling process includes first recovering lithium metal from scrap battery material, and then extracting transition metal oxides from the lithium-depleted material.

A continuous process provides direct reduction of iron ore in a solid state. Briquettes of iron ore fragments and biomass are transported through a preheating chamber and preheated to a temperature of at least 400° C. The preheated briquettes are transported through a heating/reduction chamber that has an anoxic environment, and iron ore and biomass in the briquettes are exposed to electromagnetic energy in the form of microwave energy under anoxic conditions. Microwave energy generates heat within iron ore, and biomass acts as a reductant and reduces iron ore in a solid state, as the briquettes move through the heating/reduction chamber.

A continuous process provides direct reduction of iron ore in a solid state. Briquettes of iron ore fragments and biomass are transported through a preheating chamber and preheated to a temperature of at least 400° C. The preheated briquettes are transported through a heating/reduction chamber that has an anoxic environment, and iron ore and biomass in the briquettes are exposed to electromagnetic energy in the form of microwave energy under anoxic conditions. Microwave energy generates heat within iron ore, and biomass acts as a reductant and reduces iron ore in a solid state, as the briquettes move through the heating/reduction chamber.

Embodiments described herein relate to methods of metal extraction from their ores and conversion of ores to metal carbonates for chemical storage of Carbon dioxide in mineral form. In some embodiments, metal alloys are produced directly by co-extraction of metals from a combination of the ores of respective metals in the alloy or from a combination of the oxides of respective metals.

Embodiments described herein relate to methods of metal extraction from their ores and conversion of ores to metal carbonates for chemical storage of Carbon dioxide in mineral form. In some embodiments, metal alloys are produced directly by co-extraction of metals from a combination of the ores of respective metals in the alloy or from a combination of the oxides of respective metals.