For several decades, the metallurgical industry and the research community worldwide have been challenged to develop energy-efficient and low-cost titanium production processes. The expensive and energy-consuming Kroll process produces titanium metal commercially, which is highly matured and optimized. Titanium’s strong affinity for oxygen implies that conventional Ti metal production processes are energy-intensive. Over the past several decades, research and development have been focusing on new processes to replace the Kroll process. Two fundamental groups are categorized for these methods: thermochemical and electrochemical. This literature review gives an insight into the titanium industry, including the titanium resources and processes of production. It focuses on ilmenite as a major source of titanium and some effective methods for producing titanium through extractive metallurgy processes and presents a critical view of the opportunities and challenges.

Plasma technology has emerged as a very helpful tool in a variety of sectors, notably metallurgy. Innovators and scientists are focused on the problem of finding a more ecologically friendly way of extracting titanium and iron metal from natural ilmenite concentrate for industrial applications. A direct current (DC) plasma torch operating at atmospheric pressure is used in this study to describe a decarbonization process for reducing an ilmenite concentrate. The plasma gases employed in this torch are CO₂ and CH₄. The molar ratio of the gases may be crucial for achieving a satisfactory reduction of the ilmenite concentrate. As a result, two molar ratios for CO₂/CH₄ have been chosen: 1:1 and 2:1. During torch operation, a thin layer of graphite is formed on the cathode to establish a protective barrier, prolonging the cathode’s life. The material was analyzed using X-ray diffraction (XRD) and scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS). The output gases were analyzed using mass spectrometry (MS). In addition, a thermodynamic analysis was performed to predict the development of thermodynamically stable phases. An economic assessment (including capital expenditures (CAPEX) and operating expenditures (OPEX)) and a carbon balance were developed with the feasibility of the piloting in mind.

This article presents the findings of a study on oxide reduction utilizing a novel reducing plasma torch, employing greenhouse gases such as CO₂ and CH₄ as plasma gases. The primary aim of this investigation is to establish the viability of this approach. The innovative plasma torch was employed to reduce various oxides, including aluminum oxide, iron oxide, and titanium oxide, as well as a mixed oxide composition, employing a CO₂/CH₄ molar ratio of 1:1 within a spouted bed reactor. Following plasma treatment, X-ray diffraction (XRD) analysis was conducted to examine the metallic phases, notably titanium, iron, and aluminum. SEM–EDS observations were carried out to assess microstructural changes and identify elemental compositions pre- and post-plasma treatment. The results demonstrate that within the conical section of the reactor, titanium oxide experiences partial reduction, resulting in limited titanium production, while aluminum oxide and iron oxides (magnetite and hematite) undergo reduction to yield aluminum and iron, respectively. Thermodynamic calculations, performed using Factsage software version 8.3, were utilized to predict stable-phase formations following plasma treatment for each material.