This study presents the development of an integrated hydrometallurgical process for recovering scandiumScandium (Sc) from nickel ore processing residuesNickel ore processing residue, followed by the fabrication of Al–Sc master alloysMaster alloy via a simultaneous reduction technique. The scandium recoveryScandium recovery process was designed to achieve high purity scandiumScandium oxide (Sc2O3) suitable for industrial applicationsIndustrial applications such as solid oxide fuel cells (SOFC’s) and high performance aluminum alloysAluminum alloy. The process consists of leaching, solvent extractionExtraction, Fe scrubbing, Sc stripping, precipitation, and calcinationCalcination. Pilot plant operation demonstrated a scandiumScandium extractionExtraction efficiency of over 99.9% and a final product purity exceeding 4N (Sc2O3/total rare earth oxides, TREO basis). The recovered Sc2O3 was subsequently used in an electrochemical co-reduction process with aluminumAluminum-oxide (Al2O3) to produce Al–Sc alloys. Electrolyte compositionElectrolyte composition optimizationOptimization, cyclic voltammetry, and chronopotentiometry were employed to determine the reduction potentials and improve current efficiency. The resulting Al–Sc alloys exhibited scandiumScandium contents up to 0.57 wt.%, with microstructural analysis confirming the formation of Al3Sc precipitates. This work demonstrates a viable route for valorizing nickel processingProcessing residues into high value scandiumScandium products and advanced Al–Sc alloys.