A method of producing a non-metallic feedstock powder suitable for reduction to metal comprises the steps of combining a liquid with solid metal oxide particles to form a mixture, subjecting the mixture to high-shear mixing to form a liquid suspension of metal oxide and the liquid, and drying the liquid suspension using a fluidised-bed spray-granulation process to grow a plurality particles to form the non-metallic feedstock powder. The method allows feedstock powders to be grown to desired particle sizes. The method allows production of feedstock powders having controlled compositions.

A method of producing a non-metallic feedstock powder suitable for reduction to metal comprises the steps of combining a liquid with solid metal oxide particles to form a mixture, subjecting the mixture to high-shear mixing to form a liquid suspension of metal oxide and the liquid, and drying the liquid suspension using a fluidised-bed spray-granulation process to grow a plurality particles to form the non-metallic feedstock powder. The method allows feedstock powders to be grown to desired particle sizes. The method allows production of feedstock powders having controlled compositions.

A method of electrolytic reduction of a feedstock comprising oxygen and a first metal comprises the steps of, arranging the feedstock in contact with a cathode and a molten salt within an electrolysis cell, arranging an anode in contact with the molten salt within the electrolysis cell, the anode comprising a molten second metal and applying a potential between the anode and the cathode such that oxygen is removed from the feedstock to form a reduced feedstock. The oxygen removed from the feedstock reacts with the molten second metal to form an oxide comprising the second metal. The second metal is aluminium. The reduced feedstock may comprise a proportion of aluminium.

A method of electrolytic reduction of a feedstock comprising oxygen and a first metal comprises the steps of, arranging the feedstock in contact with a cathode and a molten salt within an electrolysis cell, arranging an anode in contact with the molten salt within the electrolysis cell, the anode comprising a molten second metal and applying a potential between the anode and the cathode such that oxygen is removed from the feedstock to form a reduced feedstock. The oxygen removed from the feedstock reacts with the molten second metal to form an oxide comprising the second metal. The second metal is aluminium. The reduced feedstock may comprise a proportion of aluminium.

Disclosed methods relate to producing an aluminum-scandium (AlSc) alloy. A method can include providing an electrolyte bath comprising a first portion of at least one of ScF.sub.3 or AlF.sub.3 and a first portion of at least one of LiF, NaF, or KF; providing a cathode in electrical contact with the electrolyte bath; providing an anode in electrical contact with the electrolyte bath; adding a first portion of Sc.sub.2O.sub.3 into the electrolyte bath; reacting an aluminum ion with the cathode; applying an electric current to the cathode, thereby reacting a scandium ion with the cathode to produce the AlSc alloy.

Disclosed methods relate to producing an aluminum-scandium (AlSc) alloy. A method can include providing an electrolyte bath comprising a first portion of at least one of ScF.sub.3 or AlF.sub.3 and a first portion of at least one of LiF, NaF, or KF; providing a cathode in electrical contact with the electrolyte bath; providing an anode in electrical contact with the electrolyte bath; adding a first portion of Sc.sub.2O.sub.3 into the electrolyte bath; reacting an aluminum ion with the cathode; applying an electric current to the cathode, thereby reacting a scandium ion with the cathode to produce the AlSc alloy.

Provided herein are methods for extracting and separating metals from a mixture of metal oxides comprising: disposing a cathode comprising the mixture of metal oxides, a reducing electrode, and an anode in a solvent comprising a mixture of molten metal hydroxide salts; applying an electrical potential to a cathode, thereby reducing the mixture of metal oxides and forming a mixture of metals; selectively dissolving one or more metal ion species from the mixture of metals into the dried solvent; and applying a potential to the reducing electrode present in the dried solvent to reduce the dissolved metal ion species from the dried solvent to a respective pure metal or mixed metal.

Provided herein are methods for extracting and separating metals from a mixture of metal oxides comprising: disposing a cathode comprising the mixture of metal oxides, a reducing electrode, and an anode in a solvent comprising a mixture of molten metal hydroxide salts; applying an electrical potential to a cathode, thereby reducing the mixture of metal oxides and forming a mixture of metals; selectively dissolving one or more metal ion species from the mixture of metals into the dried solvent; and applying a potential to the reducing electrode present in the dried solvent to reduce the dissolved metal ion species from the dried solvent to a respective pure metal or mixed metal.

Provided are a method for producing a titanium-based electrolytic raw material with relatively low Al and O contents while suppressing or eliminating the use of calcium fluoride and potassium perchlorate, and a method for producing pure metallic titanium or TiAl alloy. The method for producing a titanium-based raw material for electro-refining according to the present invention is a method for producing a titanium-based raw material for electro-refining used for molten salt electro-refining to obtain pure metallic titanium or TiAl alloy, the method comprising: a reaction step of bringing a titanium compound, at least a part of the titanium compound containing titanium oxide, into contact with, in melt, pure metal and/or alloy of aluminum as a reducing agent, and a melting accelerator, and causing reactions including deoxidation of a part of O in the titanium oxide to obtain a titanium alloy product comprising Al and O, wherein the melting accelerator comprises calcium oxide (CaO), and a content of calcium oxide in the melting accelerator is 80% by mass or higher.

Provided are a method for producing a titanium-based electrolytic raw material with relatively low Al and O contents while suppressing or eliminating the use of calcium fluoride and potassium perchlorate, and a method for producing pure metallic titanium or TiAl alloy. The method for producing a titanium-based raw material for electro-refining according to the present invention is a method for producing a titanium-based raw material for electro-refining used for molten salt electro-refining to obtain pure metallic titanium or TiAl alloy, the method comprising: a reaction step of bringing a titanium compound, at least a part of the titanium compound containing titanium oxide, into contact with, in melt, pure metal and/or alloy of aluminum as a reducing agent, and a melting accelerator, and causing reactions including deoxidation of a part of O in the titanium oxide to obtain a titanium alloy product comprising Al and O, wherein the melting accelerator comprises calcium oxide (CaO), and a content of calcium oxide in the melting accelerator is 80% by mass or higher.