Abstract: A reduction process for the production of a product metal which includes the step of reacting at least one reducible metal compound and a reducing metal in a sealed reaction zone by heating the reactants without any substantial agitation from a temperature below the melting point of the reducing metal to a temperature which is both above the melting point of the reducing metal and below the temperature at which the reduction reaction between the metal compound(s) and the reducing metal will proceed spontaneously; initiating a reduction reaction between the reducible metal compound(s) and a molten reducing metal by causing the surface of the molten reducing metal to be suddenly disrupted, thereupon releasing the reaction mixture from said first reaction zone into a product collection zone while permitting the reduction reaction to continue to thereby produce a reduced metal or alloy in zero valent state; and apparatus for conducting the above process.

Abstract: This invention relates to an improved process for controlled reduction of sub-halides of certain multivalent metals, preferably titanium and zirconium. In the process a metal sub-halide is reacted with an alkali metal, such as sodium, so that the reaction temperature reaches at least about 975.degree. C. and preferably at least about the boiling point of the alkali metal halide. The reduction reaction is conducted in a manner so that the reduced metal does not contact undesirable metal, such as the outer reaction vessel.

Abstract: An improved metal reduction process permits the efficient production of metal from reducible metal compounds by means of reducing metal. Broadly, the invention relates to conducting the reaction between a reducible metal compound and a reducing metal in approximately stoichiometric amounts in an inner beneficial metal container, separated from the exterior reactor walls by an insulating material. In a preferred embodiment, the reducible metal compound and stoichiometric amount of a reducing metal are introduced into a container formed from a metal the same as the desired metal being produced or a metal alloyable therewith. The container is retained in a reaction vessel being separated from the walls of the reaction vessel by an inert insulating material. The container is then heated to a temperature which is above the melting point of the reducing metal but below the temperature at which a reduction reaction between the reducible metal compound and the molten reducing metal will proceed spontaneously.