Systems and methods for converting metal oxide to metal using metal carbide as an intermediate, include: reacting the metal oxide with carbon to produce the metal carbide, wherein the metal carbide is in a form of powder or pellets; and subjecting the metal carbide produced from the metal oxide and the carbon to electrolysis in an electrorefiner to produce and purify the metal.

A method of producing titanium metal with titanium-containing material which includes mixing, pressing and drying the titanium-containing material with a carbonaceous reducing agent to obtain a resultant as a first anode. Using a metal or an alloy as a first cathode, and using an alkali metal chloride molten salt and/or an alkaline earth metal chloride molten salt as a first electrolyte to constitute a first electrolysis system, to perform pre-electrolysis in an inert atmosphere to obtain a residual anode. After the residual anode is washed, molded and dried, using the residual anode as a second anode, using a metal or an alloy as a second cathode, using an alkali metal chloride molten salt and/or an alkaline earth metal chloride molten salt as a second electrolyte to constitute a second electrolysis system, to perform electrolysis in an inert atmosphere to obtain titanium metal powder.

A method of producing titanium metal with titanium-containing material which includes mixing, pressing and drying the titanium-containing material with a carbonaceous reducing agent to obtain a resultant as a first anode. Using a metal or an alloy as a first cathode, and using an alkali metal chloride molten salt and/or an alkaline earth metal chloride molten salt as a first electrolyte to constitute a first electrolysis system, to perform pre-electrolysis in an inert atmosphere to obtain a residual anode. After the residual anode is washed, molded and dried, using the residual anode as a second anode, using a metal or an alloy as a second cathode, using an alkali metal chloride molten salt and/or an alkaline earth metal chloride molten salt as a second electrolyte to constitute a second electrolysis system, to perform electrolysis in an inert atmosphere to obtain titanium metal powder.

A liquid transport apparatus includes: a U-shaped vessel for storing the liquid; an inverse conically shaped body which is hollow and has an opening part of an upper end and an opening part of a lower end; and a rotating disk driving motor part for rotating the inverse conically shaped body on an axis extending along a substantially vertical direction. The opening part of the lower end of the inverse conically shaped body is immersed in the liquid stored in the U-shaped vessel. In the liquid transport apparatus, an overflow opening part for keeping constant a distance between the opening part of the lower end of the inverse conically shaped body and a surface of the liquid stored in the U-shaped vessel is formed.

A liquid transport apparatus includes: a U-shaped vessel for storing the liquid; an inverse conically shaped body which is hollow and has an opening part of an upper end and an opening part of a lower end; and a rotating disk driving motor part for rotating the inverse conically shaped body on an axis extending along a substantially vertical direction. The opening part of the lower end of the inverse conically shaped body is immersed in the liquid stored in the U-shaped vessel. In the liquid transport apparatus, an overflow opening part for keeping constant a distance between the opening part of the lower end of the inverse conically shaped body and a surface of the liquid stored in the U-shaped vessel is formed.

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.

A method of producing metallic powder comprises steps of arranging a volume of feedstock comprising a plurality of non-metallic particles within an electrolysis cell, causing a molten salt to flow through the volume of feedstock, and applying a potential between a cathode and an anode such that the feedstock is reduced to metal. In preferred embodiments the feedstock is a plurality of discrete powder particles and these particles are reduced to a corresponding plurality of discrete metallic particles. In advantageous embodiments, the feedstock may be sand.