Global annual production of vanadium is approximately 100,000 tonnes; however, it remains a critical metal for steelmaking and modern industry. This study reviews the current status of vanadium smelting and recycling technologies. Approximately 90% of vanadium is produced as ferrovanadium (FeV) for use in steel alloys, although it is also utilized in titanium alloys, battery materials, and other applications. Both mineral ores and secondary waste resources serve as raw materials for vanadium production. These materials are typically subjected to roasting followed by acid or alkaline leaching to extract V₂O₅. Vanadium metal and FeV are produced from V₂O₅ primarily through aluminothermic reduction; alternatively, metallic vanadium can be manufactured via thermal reduction using Ca, Mg, or C, as well as by molten salt electrolysis. Crude vanadium is subsequently refined into high-purity metal through high-temperature vacuum treatment, electron beam melting, or molten salt electrolytic refining. Vanadium contained in steel scrap is recycled through re-melting in an electric arc furnace. Vanadium present in fly ash and spent catalysts is recovered using smelting processes similar to those applied to natural ores.
Ho-Sang Sohn (2026) studied this question.