System and process for sustainable electrowinning of metal

A system for production of metal(s) from a metal ore containing a metal oxide, the system comprising:

• a chlorination reactor containing an aqueous HCl solution, wherein the chlorination reactor is configured for non-carbothermic chlorination of the metal oxide of the metal ore with the aqueous HCl solution to metal chloride(s), wherein the metal oxide comprises an oxide of at least one of Fe or a rare-earth metal;
• an electrolysis reactor including an electrochemical cell, the electrochemical cell including an anode and a cathode provided in a molten salt, wherein the anode includes graphite coated with RuO2, IrO2, or their combination, and the electrolysis reactor is configured for molten salt electrolysis of the metal chloride(s) to metal(s) and chlorine gas;
• and
• optionally a reactor for converting the chlorine gas generated in the electrolysis reactor to HCl, the HCl being optionally transferred to the chlorination reactor for non-carbothermic chlorination of the metal oxide.