Abstract: A process for minimising reoxidation of reduced material is disclosed. The process applies to reduced material that has been formed by a process of electrochemically reducing a metal oxide feed material, such as titania, in a solid state in an electrolytic cell containing a molten electrolyte. The process for minimising reoxidation includes applying an electrical potential to reduced material at least while the reduced material remains immersed in the molten electrolyte.

Abstract: An electrolytic cell (1) for reducing metal oxide powders and/or pellets in a continuous or semi-continuous manner, the cell includes a cathode (25) in the form of a plate that has an upper surface for supporting metal oxide powders and/or pellets. The plate is supported for movement so as to cause the metal oxide on the upper surface to move toward a forward end of the plate while immersed in a molten electrolyte (21). The cell includes multiple anodes (23) and support structures (63,65) that separately support the cathode and the anodes from above the cell. In a preferred embodiment the anode support structure enables adjustment of the spacing of the anodes above the upper surface of the cathode.

Abstract: A metal oxide feed material for an electrochemical reduction process is disclosed. The feed material is in the form of powders and/or pellets that have sufficient porosity, typically 35-60%, to enable penetration of molten electrolyte into the powders and/or pellets during the course of an electrochemical reduction process in an electrolytic cell and subsequent washing of electrolyte from the powders and/or pellets after the powders and/or pellets are discharged from the cell. A process for preparing the metal oxide feed material is also disclosed.

Abstract: A process for electrochemically reducing metal oxide feed material in a solid state is disclosed. The process includes the steps of agitating an electrolyte and metal oxide powders in the electrolyte and applying an electrical potential across a cathode in contact with the electrolyte and an anode and electrochemically reducing the metal oxides.