ABSTRACTThe thermal reduction of ilmenite to produce a high grade titania slag and pig iron byproduct using a d.c. transferred-arc plasma furnace has been investigated. Small-scale (50 kVA) batch tests were conducted on three different ilmenite concentrates of widely differing chemical compositions and geological histories to assess the suitability of this reactor configuration for ilmenite smelting. The effects of reducing agent particle size and excess carbon on slag grade, titanium and iron recoveries, and reducing agent efficiency are discussed. A d.c. plasma furnace appears to be an ideal reactor for ilmenite smelting, although accurate control of the furnace thermal balance is essential if reaction between furnace refractories and the titania slag is to be avoided.