From Ti-Bearing Feed to Aluminous Slag: A Critical Review of Sequential Recovery and Valorization Pathways in Aluminothermic Titanium Processing

Aluminothermic processing of titanium-bearing resources is usually judged by alloy yield, titanium recovery, and alloy chemistry, while the co-generated aluminous slag is treated as a secondary residue. This critical narrative review reframes that slag as a multi-resource stream whose value depends on phase chemistry, elemental deportment, entrained metal, cooling history, and downstream separability, rather than on bulk Al₂O₃ content alone. The evidence base comprises 99 cited publications, predominantly from 2020 to August 2026. Because the original database exports, duplicate logs, exclusion records, exact query dates, and screening histories were not retained, the work is not presented as a PRISMA systematic review and should not be interpreted as exhaustive; the later verification search of 20 August 2026 is reported separately and does not reconstruct the discovery-stage corpus. Evidence is appraised independently by provenance/transferability (D1, D2, T1, T2, or contextual) and by technology scale. Direct evidence is strongest for aluminothermic production of FeTi or Ti–Al alloys and for refractory or ceramic use of real ferrotitanium slag, whereas hydrometallurgical Ti recovery is supported mainly by phase-matched transfer evidence from other Ti-bearing slags. The proposed sequence is to recover entrained FeTi first, evaluate residual Ti second, assess Al recovery or direct Al-bearing phase use third, and then consider refractory or advanced-ceramic applications before bulk use. A six-gate framework links mineralogy, liberation, product qualification, environmental closure, and industrial feasibility. Two worked applications to published real-material aluminothermic cases show how the gates identify both promising routes and missing evidence; importantly, a technical pass at an individual gate does not establish economic feasibility. Slag engineering should therefore begin during charge design, reduction, alloy–slag separation, and cooling.

Aluminothermic slag; Titanium ores; Ilmenite; Ferrotitanium; Alumina recovery; Slag valorization

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