Methods and systems for converting metal oxides to metal using metal carbide as an intermediate

A method for converting metal oxide to metal using metal carbide as an intermediate, the method comprising:

• 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 a first electrorefiner to produce and purify the metal, wherein the electrolysis comprises:
• providing the first electrorefiner into which the metal carbide is transferred, the first electrorefiner comprising a bath vessel holding a dry salt mixture, the dry salt mixture comprising a dry salt medium, and the dry salt mixture is configured to be heated to form a molten salt bath;
• heating the dry salt mixture to form the molten salt bath;
• disposing a cathode assembly into the molten salt bath;
• depositing the metal carbide into an anode feed basket and disposing the anode feed basket with the metal carbide therein into the molten salt bath;
• and
• coupling a power supply to the anode feed basket and the cathode assembly, wherein the power supply produces a current flow causing oxidization of the metal at the anode feed basket, and reduction of the metal on the cathode assembly as electrorefined dendritic metal which includes salt, wherein graphite and salt accumulates in the anode feed basket;
• the method further comprising processing the electrorefined dendritic metal which includes salt in a salt recovery chamber to evaporate the salt from the dendritic metal by heating to between about 700° C. and about 1100° C., and
• processing the anode feed basket including the accumulated graphite and salt therein in the salt recovery chamber to evaporate the salt from the anode feed basket by heating to between about 700° C. and about 900° C.