Innovation
TiBeRIUM develops and demonstrates cutting-edge extraction and processing technologies that eliminate carbon from Titanium and Beryllium value chains, powered by digital innovation and circular economy principles.
Titanium value chain
From raw ilmenite and titanomagnetite ores in Central Asia to pure Ti metal and high-performance alloys, through novel hydrogen-based and electrolytic processes.
Hydrogen Direct Reduction
TiBeRIUM replaces carbon with hydrogen in Ti slag production, eliminating the CO₂ emissions inherent in conventional carbochlorination (Kroll process). Three complementary approaches are demonstrated:
- Fluidized bed reactor using H₂ gas for gas-solid reduction of ilmenite at TUBAF
- Rotary kiln pilot plant (100 kg batches) for large-scale H₂ reduction at BAM
- Hydrogen Plasma Smelting Reduction (HPSR) for direct melting and reduction at EKTU
- Use of ammonia (NH₃) as an alternative hydrogen carrier for transportability
Hydrogen replaces carbon as reductant,
producing TiO₂-rich slag and metallic iron
with zero CO₂ process emissions.
Solid-State Electrolysis
A CO₂-free process for producing pure Ti metal through electrolytic reduction of TiO₂ powder in molten salt, using a novel multi-cathode inert anode design developed at TUBAF.
- Porous metal cathode design optimized for TiO₂ absorption and complete reduction
- Innovative inert anode producing pure O₂ instead of CO₂
- Multi-cathode arrangement enabling semi-continuous to quasi-continuous operation
- Scale-up from 1 kg to 10 kg electrolyte mass for industrial validation
Electrolytic reduction produces
oxygen-free Ti metal and pure O₂
with zero greenhouse gas emissions.
Aluminothermic Reduction
A CO₂-free process for producing Ti alloys (FeTi and CuTi) using an Electric Arc Furnace (EAF), bypassing conventional multi-step processes and achieving major energy savings.
- Direct aluminothermic reduction of TiO₂ slag and ilmenite with Al scrap
- Production of FeTi alloys meeting ISO 5454-1980 standards
- CuTi alloys from Ti-rich slags at large scale (>100 kg, TRL 7)
- Up to 60% energy savings compared to conventional melting processes
Aluminothermic reduction eliminates
intermediate steps, producing Ti alloys
directly in a single EAF operation.
Beryllium value chain
From complex Karadzhal ore in Kazakhstan through innovative mineral processing to refined Be metal, Cu-Be and Al-Be master alloys at the ULBA metallurgical plant.
Novel Mineral Processing
TiBeRIUM develops an innovative beneficiation flowsheet for the complex Karadzhal deposit, where beryllium (BeO 0.1-0.3%) is hosted primarily in chrysoberyl and bertrandite minerals.
- LIBS sensor integration for rapid Be-zone screening and mineral mapping
- Electric Pulse Fragmentation (EPF) for selective liberation of Be-bearing phases
- Purpose-developed flotation collectors selective toward Be-bearing minerals
- Column flotation for achieving target grade of minimum 4% BeO concentrate
- Multi-commodity extraction of fluorite, tungsten (W), and scandium (Sc)
Innovative beneficiation achieves
high-grade Be concentrate from complex
ore with multiple commodity recovery.
Downstream Be Processing
At the ULBA metallurgical plant, the high-quality Be concentrate is refined to produce technical-grade beryllium metal and advanced alloys for European end-users.
- Optimized sulphate method with reduced energy consumption (25% lower)
- Improved vacuum distillation for higher purity Be metal (>99.5%)
- Cu-Be master alloys (10% Be) meeting EN 1981 specifications
- Al-Be master alloys (5% Be) meeting EN 575 specifications
- Enhanced occupational safety with Be aerosol emissions ≤ 0.1 μg/m³
Refined Be products validated by
EU end-users for electronics,
aerospace, and green technologies.
Digitalization across the value chain
Digital Twin of Mining & Processing
A validated digital twin combining experimental data with historical datasets to replicate and optimise beneficiation flowsheets for both Ti and Be ores. The twin captures particle-level properties and enables predictive scenario testing.
- Geometallurgical modelling linking geology to metallurgy
- Process simulation using HSC Chemistry with custom modules
- Real-time process monitoring and predictive maintenance
Satellite Environmental Monitoring
Using EU Copernicus Sentinel data and hyperspectral sensors to monitor GHG emissions (CO₂, methane), soil moisture, water quality, and ecosystem impacts at mine sites in Kazakhstan and Uzbekistan.
Closing the loop
Slag Valorisation for Building Materials
Ti-slag by-products from hydrogen reduction and aluminothermic processes are transformed into innovative, low-CO₂ building materials as sustainable alternatives to cement-based products.
- Calcium Aluminate Cement (CAC) binders for rapid-hardening applications
- Calcium Sulfoaluminate (CSA) cement blends for repair mortars
- Alkali-Activated Materials (AAM) for tiles and pavers
- Up to 80 kg of TiBeRIUM residues utilized in demo building products
Multi-Commodity Extraction
Beyond Ti and Be, TiBeRIUM targets recovery of additional valuable commodities from the same ore streams: fluorite, tungsten (W), scandium (Sc), vanadium (V), and iron (Fe).