Embodiments relate to systems and methods for regenerating and recirculating a CO, H.sub.2 or combinations thereof utilized for metal oxide reduction in a reduction furnace. The reduction furnace receives the reducing agent, reduces the metal oxide, and generates an exhaust of the oxidized product. The oxidized product is transferred to a mixing vessel, where the oxidized product, a calcium oxide, and a vanadium oxide interact to regenerate the reducing agent from the oxidized product. The regenerated reducing agent is transferred back to the reduction furnace for continued metal oxide reductions.

Integrated recycling method and processes including recycling spent catalyst to produce one or more water-soluble metal salts and one or more water-insoluble tail byproducts, and recycling rechargeable batteries to produce one or more battery-grade metals and one or more pure metallic byproducts, wherein the water insoluble tail byproduct is a feedstock in recycling the rechargeable batteries, the impure metallic byproduct is a feedstock in recycling the spent catalyst, or both.

A method for recovering Vanadium from a secondary source such as fly ash. Leaching is involved using single or combined acids such as hydrochloric and sulfuric in a temperature range of 20° C. and 100° C. The leaching is performed in sequential operations with recovery of Vanadium in the range of 92%. The recovered Vanadium can be formulated into an electrolyte for redox batteries

A method for recovering Vanadium from a secondary source such as fly ash. Leaching is involved using single or combined acids such as hydrochloric and sulfuric in a temperature range of 20° C. and 100° C. The leaching is performed in sequential operations with recovery of Vanadium in the range of 92%. The recovered Vanadium can be formulated into an electrolyte for redox batteries

The invention provides a method for the recovery of a metal-containing product (M.sub.Prod) comprising: providing a composite material comprising a matrix of oxidised reductant (R.sub.o), a product metal (M.sub.P) dispersed in the matrix of oxidised reductant (R.sub.o), and one or more metal compounds (M.sub.PC.sub.R) of the product metal (M.sub.P) in one or more oxidation states dispersed in the matrix of oxidised reductant (R.sub.o); and treating the composite material to at least partially remove the one or more metal compounds (M.sub.PC.sub.R) from the matrix of oxidised reductant (Ro) to form the metal-containing product (M.sub.Prod).

The invention provides a method for the recovery of a metal-containing product (M.sub.Prod) comprising: providing a composite material comprising a matrix of oxidised reductant (R.sub.o), a product metal (M.sub.P) dispersed in the matrix of oxidised reductant (R.sub.o), and one or more metal compounds (M.sub.PC.sub.R) of the product metal (M.sub.P) in one or more oxidation states dispersed in the matrix of oxidised reductant (R.sub.o); and treating the composite material to at least partially remove the one or more metal compounds (M.sub.PC.sub.R) from the matrix of oxidised reductant (Ro) to form the metal-containing product (M.sub.Prod).

A method of producing a composite material comprising: supplying a metal compound (M.sub.PC) of a product metal (M.sub.P) and a reductant (R) capable of reducing the metal compound (M.sub.PC) of the product metal (MP) to a reactor; forming a composite material comprising a matrix of oxidised reductant (R.sub.0) of the reductant (R), the product metal (M.sub.P) dispersed in the matrix of oxidised reductant (R.sub.0), and at least one of (i) one or more metal compounds (M.sub.PC.sub.R) of the metal compound (M.sub.PC) in one or more oxidation states and (ii) the reductant (R); and recovering the composite material from the reactor, wherein the metal compound (M.sub.PC) of the product metal (M.sub.P) is fed to the reactor such that it is in excess relative to the reductant (R).

A method of producing a composite material comprising: supplying a metal compound (M.sub.PC) of a product metal (M.sub.P) and a reductant (R) capable of reducing the metal compound (M.sub.PC) of the product metal (MP) to a reactor; forming a composite material comprising a matrix of oxidised reductant (R.sub.0) of the reductant (R), the product metal (M.sub.P) dispersed in the matrix of oxidised reductant (R.sub.0), and at least one of (i) one or more metal compounds (M.sub.PC.sub.R) of the metal compound (M.sub.PC) in one or more oxidation states and (ii) the reductant (R); and recovering the composite material from the reactor, wherein the metal compound (M.sub.PC) of the product metal (M.sub.P) is fed to the reactor such that it is in excess relative to the reductant (R).

The present invention relates to a method for converting and separating vanadium, titanium, and iron from the vanadium-titanium-iron concentrate in one step, which includes the steps as below. (1) The vanadium-titanium-iron concentrate is mixed and roasted together with addition agent and reducing, agent, and thereby vanadium-containing pig iron and vanadium enriched slag are obtained. (2) The vanadium titanium enriched slag is leached in water and filtered, and thereby vanadium-containing solution and titanium slag are obtained. The technical features of the present invention are as below. By the new process of sodium reduction coupling, a new system of low-temperature smelting multiphase reaction separation is constructed. The reduction of iron, sodiumizing of vanadium, and the melting separation process of the vanadium titanium enriched slag and the iron are achieved in one step. Three products, i.e., the vanadium-containing pig iron, the vanadium-containing solution, and the titanium slag are produced.

The present invention relates to a method for converting and separating vanadium, titanium, and iron from the vanadium-titanium-iron concentrate in one step, which includes the steps as below. (1) The vanadium-titanium-iron concentrate is mixed and roasted together with addition agent and reducing, agent, and thereby vanadium-containing pig iron and vanadium enriched slag are obtained. (2) The vanadium titanium enriched slag is leached in water and filtered, and thereby vanadium-containing solution and titanium slag are obtained. The technical features of the present invention are as below. By the new process of sodium reduction coupling, a new system of low-temperature smelting multiphase reaction separation is constructed. The reduction of iron, sodiumizing of vanadium, and the melting separation process of the vanadium titanium enriched slag and the iron are achieved in one step. Three products, i.e., the vanadium-containing pig iron, the vanadium-containing solution, and the titanium slag are produced.