A method and system for recovering a high yield of low carbon ferrochrome metal from chromite ore and low carbon ferrochrome metal produced by the method. A thermochemistry calculated mixture of feed materials including aluminum granules, burnt limestone, and chromite ore are provided into a DC plasma arc furnace. The aluminum granules are produced from aluminum scrap. The feed materials are heated upon entering the furnace free board through a feed mix injection system, whereupon the aluminum in the aluminum granules produces an exothermic reaction reducing the chromium oxide and iron oxides in the chromite ore to produce molten low carbon ferrochrome metal with molten slag floating thereon. The molten low carbon ferrochrome metal is extracted, solidified into ingots, crushed into coarse pieces or fines of low carbon ferrochrome metal product. The molten slag is extracted, quenched and solidified into slag particles product.

A method and system for recovering a high yield of low carbon ferrochrome metal from chromite ore and low carbon ferrochrome metal produced by the method. A thermochemistry calculated mixture of feed materials including aluminum granules, burnt limestone, and chromite ore are provided into a DC plasma arc furnace. The aluminum granules are produced from aluminum scrap. The feed materials are heated upon entering the furnace free board through a feed mix injection system, whereupon the aluminum in the aluminum granules produces an exothermic reaction reducing the chromium oxide and iron oxides in the chromite ore to produce molten low carbon ferrochrome metal with molten slag floating thereon. The molten low carbon ferrochrome metal is extracted, solidified into ingots, crushed into coarse pieces or fines of low carbon ferrochrome metal product. The molten slag is extracted, quenched and solidified into slag particles product.

Provided is sponge titanium produced by the Kroll method, in which the total of a chlorine content and a magnesium content is 350 ppm by mass or lower, and a filling density is 1.65 g/cm.sup.3 to 1.95 g/cm.sup.3. The present invention can provide sponge titanium for large ingot production that is difficult to cause problems due to chloride inclusion at the time of melting production of the large ingot by a melting method not associated with compression molding and has easy component control and also provide a method for industrially efficiently producing the sponge titanium.

Provided is sponge titanium produced by the Kroll method, in which the total of a chlorine content and a magnesium content is 350 ppm by mass or lower, and a filling density is 1.65 g/cm.sup.3 to 1.95 g/cm.sup.3. The present invention can provide sponge titanium for large ingot production that is difficult to cause problems due to chloride inclusion at the time of melting production of the large ingot by a melting method not associated with compression molding and has easy component control and also provide a method for industrially efficiently producing the sponge titanium.

Devices, systems, and methods for metals production are disclosed. In a first embodiment, a first portion of an ore is reduced, producing metals. A portion of the metals are stripped, complexed, or a combination thereof, into a supercritical carbon dioxide stream.

A method of processing finely divided reactive particulates (R.sub.Particulate) and forming a product comprising: providing a composite material comprising finely divided reactive particulates (R.sub.Particulate) dispersed in a protective matrix; at least partially exposing the finely divided reactive particulates (R.sub.Particulate); and forming the product.

A method of processing finely divided reactive particulates (R.sub.Particulate) and forming a product comprising: providing a composite material comprising finely divided reactive particulates (R.sub.Particulate) dispersed in a protective matrix; at least partially exposing the finely divided reactive particulates (R.sub.Particulate); and forming the product.

A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.

A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.

The present disclosure relates to a metal oxide reduction method and, specifically, to a metal oxide reduction method which, in producing a high-grade alloy metal using a metal oxide as a raw material, enables operation in the atmosphere by moving away from an existing production process in an inert gas atmosphere, and is easy to commercialize and can maximize efficiency, as an eco-friendly method is used.