Introduction to the Research History of Global Titanium Scrap Recycling and Utilization

Possessing outstanding properties such as light weight, high strength and excellent corrosion resistance, titanium and titanium alloys are indispensable strategic metals widely applied in aerospace, military industry, medical treatment, chemical engineering and other fields. Nevertheless, Titanium Materials feature low processing yield and high production energy consumption. Hence, recycling and reusing titanium scrap serves as a core approach to cut costs, secure supply chain stability and advance low-carbon green development.

In the previous paper “Analysis of the Whole Recycling Chain of Titanium Scrap: Source Composition and Classification System”, we illustrated the sources and classification system within the full titanium scrap recycling chain. This paper focuses on the research history and technological evolution of titanium scrap recycling. It systematically sorts out the development progress, technological breakthroughs and policy arrangements in the United States, Russia, Japan and China, providing references for the advancement of China’s titanium circular industry.

1. Initiation and Industrialization of Global Titanium Scrap Recycling

Research on the recycling of titanium and titanium alloy scrap was firstly launched abroad in the early 1960s, and relevant technologies achieved industrial-scale recycling in the early 1970s. In the early stage, studies centered on addressing high costs and resource shortages of titanium materials for military and aerospace use. Vacuum Arc Remelting (VAR) emerged as the primary technology, driving titanium scrap recycling to evolve from simple reuse to standardized and large-scale remanufacturing.

Driven by growing demands from civil aviation and high-end manufacturing, technologies including Electron Beam Cold Hearth Melting (EB-CHM) and Hydrogenation-Dehydrogenation (HDH) powder production have been developed and upgraded. Titanium scrap recycling has expanded from single remelting to diversified development modes covering high-purity purification, closed-loop recycling and powder preparation.

2. Research and Development History of Titanium Scrap Recycling in Major Countries

2.1 The United States: Military-driven Development, Standard Guidance and Leading Closed-loop Recycling

The U.S. boasts an early-developed titanium industry, and its titanium scrap research progressed alongside aerospace and military demands. In 1954, Henderson Titanium Plant successfully cast titanium ingots using 100% titanium scraps via vacuum arc remelting, which were applied to aero-engine compressor disks. Titanium scrap fell into short supply in the 1960s. Around 30% of scrap was remelted into titanium ingots, 32% was utilized in the steel industry and 8% was adopted by the aluminum industry.

Civil aviation became the major source of titanium scrap in the 1970s. In the 1980s, industrial-grade EB-CHM furnaces realized 100% scrap feeding. The research focus shifted to low-cost EB refining and aviation-grade closed-loop recycling in the 1990s. ASTM B901-07, the international specification for titanium scrap trade, was issued in 2007. The National Defense Authorization Act set targets for high material utilization in 2014. Combined EB and plasma furnace technology as well as powder closed-loop recycling were further promoted after 2020. The output of titanium scrap reached 110 kilotons in 2023 with a recycling rate of 86%. The country plans to greatly expand recycling processing capacity by 2026.

2.2 Russia: Military-oriented Research, In-depth Technological Development and Green Transition

Russia founded a special laboratory for titanium scrap recycling in 1957. The Skat project was implemented from 1982 to 1990 to raise the comprehensive utilization rate of titanium materials. In the early period, one third of titanium scrap was used in steel manufacturing, and 29% was remelted into new titanium ingots. The actual proportion of recycled scrap in furnace burden reached 50% in batch production.

A 150kW EB furnace was put into operation in 1985 to achieve efficient oxygen removal. Mass production of titanium powder for military powder metallurgy components was realized in 1987. EB furnace capacity was upgraded in the 1990s. Titanium scrap was listed as a strategic resource in 2013, and preferential income tax policies were introduced to support recycling enterprises in 2021. Russia has formed two core technologies, EB-CHM remelting and HDH powder production. Its recycling industry has gone through four stages: military demand-driven initiation, deep deoxidation, commercial powder production and high-purity green recycling, forming a complete industrial technological chain. In 2023, 8.4 kilotons of titanium scrap were recycled, accounting for 37% of raw material consumption.

2.3 Japan: Dominant Pure Titanium Scrap, Refined Management and Mandatory Recycling Policies

Pure titanium materials account for about 90% of titanium products in Japan, making scrap recycling less difficult. Half of the titanium scrap is remelted into titanium ingots, and the rest is consumed by the steel industry or exported overseas. Japan attaches great importance to classified collection, storage and automatic treatment of scrap. Technologies such as crushing, cleaning and chlorination recycling were matured in the 1980s.

The Effective Resource Utilization Promotion Act categorized titanium scraps as designated by-products in 1991, mandating enterprises to achieve a recycling rate above 90%. New technologies including molten salt electrolysis deoxidation have been developed in the 21st century. Japan’s annual titanium scrap resource stood at 10 kilotons in 2024 with a recycling rate of 92%, owning a highly refined and standardized recycling system.

2.4 China: Synchronized Development, Independent Technological Breakthrough and Full-industry-chain Layout

China’s titanium industry took shape in the 1950s. Commercial production of Titanium Processing materials was realized in 1964, and titanium scrap recycling research started simultaneously. Baoti Group built a 1,000-ton annual-capacity recycling production line in 1968, marking the start of large-scale industrial recycling in China. Technologies for bulk scrap recycling were mastered in the 1970s, and research on TC4 titanium alloy scrap recycling commenced in the late 1980s.

China released industrial and national standards for titanium scrap successively in 1993 and 2007. The 14th Five-Year Plan set a target of over 90% titanium scrap recycling rate. Scrap-based powder production was listed as a key development direction in 2022. Leading enterprises upgraded VAR and EB furnace equipment, establishing a full-process industrial chain covering scrap collection, classification, smelting and rolling. The recycling utilization rate of titanium chips has hit 92%. Mature recycling methods including hydrometallurgy, electrothermal reduction and electric arc furnace smelting have been applied, and remarkable progress has been made in closed-loop recycling of medical waste titanium materials.

3. Core Indicator Comparison of Titanium Scrap Recycling in Four Countries

4. Conclusion

Titanium scrap recycling has evolved from simple technological research into a strategic industry integrating standards, policies, technologies and industrial chains. The United States leads the global development with advanced standards and closed-loop recycling modes. Russia develops high-purity recycling technologies relying on solid military industrial foundations. Japan maintains high recycling efficiency via meticulous management. China achieves rapid progress from independent exploration to complete industrial chain construction.

Currently, the global titanium circular industry trends toward high purification, powder production, full closed-loop operation and low-carbon manufacturing. Drawing on international experience, China shall improve classification standards, upgrade high-end recycling technologies and build interconnected closed-loop chains covering military, civil and medical fields. It will further raise titanium scrap utilization efficiency, reduce dependence on imported strategic resources, and drive the titanium industry toward high-quality development featuring environmental friendliness, high efficiency and sustainability.