Abstract: A process for producing zirconium or hafnium metals by the reduction of their tetrachlorides with an excess of molten magnesium is provided with increased reactor capacity, increased yield per run, and improved economy by virtue of withdrawal of magnesium chloride as formed during the reaction, which permits subsequent separation and recovery of excess magnesium from the product by a simple distillation and in a form suitable for direct utilization in a second or subsequent reduction. Apparatus is provided which accommodates both the reduction process and the distillation in convenient fashion.