A method of forming an alloy includes disposing a first metal oxide and a second metal oxide in a molten salt. The molten salt is in contact with a working electrode and a counter electrode. An electrical potential is applied between the counter electrode and the working electrode to co-reduce the first metal oxide and the second metal oxide to form a first metal and a second metal, respectively.

A method for recycling metallic material produced by an electrochemical material removal process. The method includes flowing an electrolyte solution between an anode workpiece and a cathode tool in a first electrolytic process, the first electrolytic process including applying a first electrolytic current and voltage between the anode workpiece and the cathode tool and thereby causing metal ions to be removed from the anode workpiece and dissolved and substantially retained in the electrolyte solution. The electrolyte solution with the metal ions therein is passed between an electrowinning cathode and an electrowinning anode in a second electrolytic process, the second electrolytic process including applying a second electrolytic current and voltage between the electrowinning cathode and the electrowinning anode and thereby causing the metal ions to be removed from the electrolyte solution and deposited onto the electrowinning cathode.

A method for recycling metallic material produced by an electrochemical material removal process. The method includes flowing an electrolyte solution between an anode workpiece and a cathode tool in a first electrolytic process, the first electrolytic process including applying a first electrolytic current and voltage between the anode workpiece and the cathode tool and thereby causing metal ions to be removed from the anode workpiece and dissolved and substantially retained in the electrolyte solution. The electrolyte solution with the metal ions therein is passed between an electrowinning cathode and an electrowinning anode in a second electrolytic process, the second electrolytic process including applying a second electrolytic current and voltage between the electrowinning cathode and the electrowinning anode and thereby causing the metal ions to be removed from the electrolyte solution and deposited onto the electrowinning cathode.

A method for extracting metals from saprolite laterite nickel ore includes: separating and grinding the saprolite laterite nickel ore to obtain a laterite nickel ore powder; mixing the laterite nickel ore powder, water, an acid, and a reducing agent to perform atmospheric pressure acid leaching to obtain a leaching residue and a leaching solution; adding a soluble fluoride salt and sodium salt to the leaching solution to obtain a silicon-aluminum residue and a de-silicon-aluminumed liquid; adding a phosphorus source to the de-silicon-aluminumed liquid, and performing solid-liquid separation to obtain an iron phosphate and a de-ironed liquid; subjecting the de-ironed liquid to a one-step cyclone electrolysis to obtain a zinc-chromium alloy and a one-step cyclone electrolyzed liquid; subjecting the one-step cyclone electrolyzed liquid to a two-step cyclone electrolysis to obtain a nickel-cobalt alloy, a manganese oxide, and a two-step cyclone electrolyzed liquid; and adding sodium carbonate to the two-step cyclone electrolyzed liquid for a precipitation reaction to obtain magnesium carbonate and a de-magnesiumed liquid. The disclosure achieves the short-flow separation and extraction of different valuable metal elements such as zinc, chromium, nickel, cobalt, and manganese in the saprolite laterite nickel ore, which is an economic, efficient, green, and environment-friendly extraction process.

A method for extracting metals from saprolite laterite nickel ore includes: separating and grinding the saprolite laterite nickel ore to obtain a laterite nickel ore powder; mixing the laterite nickel ore powder, water, an acid, and a reducing agent to perform atmospheric pressure acid leaching to obtain a leaching residue and a leaching solution; adding a soluble fluoride salt and sodium salt to the leaching solution to obtain a silicon-aluminum residue and a de-silicon-aluminumed liquid; adding a phosphorus source to the de-silicon-aluminumed liquid, and performing solid-liquid separation to obtain an iron phosphate and a de-ironed liquid; subjecting the de-ironed liquid to a one-step cyclone electrolysis to obtain a zinc-chromium alloy and a one-step cyclone electrolyzed liquid; subjecting the one-step cyclone electrolyzed liquid to a two-step cyclone electrolysis to obtain a nickel-cobalt alloy, a manganese oxide, and a two-step cyclone electrolyzed liquid; and adding sodium carbonate to the two-step cyclone electrolyzed liquid for a precipitation reaction to obtain magnesium carbonate and a de-magnesiumed liquid. The disclosure achieves the short-flow separation and extraction of different valuable metal elements such as zinc, chromium, nickel, cobalt, and manganese in the saprolite laterite nickel ore, which is an economic, efficient, green, and environment-friendly extraction process.

A low heat, electrochemical cascade process generates iron metal (Fe.sub.2) from iron ore and a sequence of alkaline electrolytic solutions. An intermediate phase favors iron oxide in a layered double hydroxide (LDH) form resulting from conditioning silicates in the alkaline solution over chemically inert Fe.sub.3O.sub.4 formation. The alkaline electrolytic solution mitigates production of hydrogen gas over acidic approaches by inhibiting a hydrogen evolution reaction (HER) that forms parasitic hydrogen gas. An electrolyte containment generates an electrolyte flow for the cascading electrochemical reaction as the raw iron oxide transforms to iron metal while avoiding conventional shortcomings of low value products of Fe.sub.3O.sub.4 (magnetite) and hydrogen gas, and instead favors generation of iron metal. Additional electrolyte salts can further form iron alloys.

A low heat, electrochemical cascade process generates iron metal (Fe.sub.2) from iron ore and a sequence of alkaline electrolytic solutions. An intermediate phase favors iron oxide in a layered double hydroxide (LDH) form resulting from conditioning silicates in the alkaline solution over chemically inert Fe.sub.3O.sub.4 formation. The alkaline electrolytic solution mitigates production of hydrogen gas over acidic approaches by inhibiting a hydrogen evolution reaction (HER) that forms parasitic hydrogen gas. An electrolyte containment generates an electrolyte flow for the cascading electrochemical reaction as the raw iron oxide transforms to iron metal while avoiding conventional shortcomings of low value products of Fe.sub.3O.sub.4 (magnetite) and hydrogen gas, and instead favors generation of iron metal. Additional electrolyte salts can further form iron alloys.