A system for processing red mud comprising: a first heating section controlled to heat red mud to a first temperature; a second heating section controlled to heat the red mud to a second temperature lower than the first temperature; a crusher configured to grind the red mud to a predetermined particle size; and one or more separators for physically extracting at least iron and aluminum from the red mud.

The invention relates to a method for operating a fluidized bed boiler, comprising carrying out the combustion process with a fluidized bed comprising ilmenite particles, wherein the average residence time of the ilmenite particles in the boiler is at least 75 hours. The invention further relates to ilmenite particles obtainable by a corresponding method and the use of said ilmenite particles as oxygen-carrying material.

A method (500) for producing a titanium product is disclosed. The method (500) can include obtaining TiO.sub.2-slag (501) and reducing impurities in the TiO.sub.2-slag (502) to form purified TiO.sub.2 (503). The method (500) can also include reducing the purified TiO.sub.2 using a metallic reducing agent (504) to form a hydrogenated titanium product comprising TiH.sub.2 (505). The hydrogenated titanium product can be dehydrogenated (506) to form a titanium product (508). The titanium product can also be optionally deoxygenated (507) to reduce oxygen content.

A method (10) for preparing a leach feed material, the method (10) comprising the steps of: passing an ore or concentrate containing vanadium and iron to a reduction step (12) to form a reduced ore or concentrate; and passing the reduced ore or concentrate to a ferric leach step (14) to produce a ferric leachate containing iron and a ferric leach residue containing vanadium,
wherein the ferric leach residue is suitable for use as the leach feed material for extracting and recovering vanadium.

The invention relates to a feedstock composite comprising a metal oxide fraction and a carbonaceous fraction, a binder composition and the use thereof for obtaining the feedstock composite. Further, the invention refers to a method for obtaining the feedstock composite.

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.

A system for the recovery of titanium, titanium alloys, zirconium and zirconium alloys is disclosed. The system is fed with a mixture of chips including titanium chips, titanium alloy chips, zirconium chips and zirconium alloy chips, ferromagnetic chips and electrically conductive non-ferromagnetic chips. The system has at least one magnetic separator, a drying device and an Eddy current separator.

A method (400) for producing a titanium product is disclosed. The method (400) can include obtaining TiO.sub.2-slag (401), and producing a titanium product from the TiO.sub.2-slag using a metallic reducing agent (402) at a moderate temperature and a pressure to directly produce a titanium product chemically separated from metal impurities in the TiO.sub.2 slag (403). The titanium product can comprise TiH.sub.2 and optionally elemental titanium. Impurities in the titanium product can then removed (404) by leaching, purifying and separation to form a purified titanium product.

The invention relates to a method for operating a fluidized bed boiler, comprising carrying out the combustion process with a fluidized bed comprising ilmenite particles, wherein the average residence time of the ilmenite particles in the boiler is at least 75 hours. The invention further relates to ilmenite particles obtainable by a corresponding method and the use of said ilmenite particles as oxygen-carrying material.

Disclosed herein is a novel approach to the chemical synthesis of titanium metal from a titanium oxide source material, such as a mineral comprising titanium. In the approach described herein, a titanium oxide source is reacted with Mg vapor to extract a pure Ti metal. The method disclosed herein is more scalable, cheaper, faster, and safer than prior art methods.