Abstract: A method and apparatus for continuously producing metals such as zirconium, hafnium, titanium, niobium, vanadium, silicon and tantalum. The corresponding metal halide is reacted with a metallic reducing agent such as aluminum, calcium, magnesium and sodium in a reactor where the reaction takes place at a temperature where the metal reducing agent is below its vaporization temperature and where the metal halide is above its vaporization temperature. The metal formed by the reaction is recovered from the reactor by collecting it in a pool of molten product metal contained in a cold wall induction heated receptacle in the reactor from which the metal product is removed.

Abstract: A crucible for containing molten mixtures of magnesium and magnesium chloride comprises an outer relatively thick base layer of austenitic stainless steel covered inside with a relatively thin layer of mild carbon steel. The stainless layer provides strength and good creep resistance at 850.degree. C., and the mild steel layer protects the stainless layer from chemical attack by liquid magnesium. The carbon steel lining is applied by weld overlaying.

Abstract: A process is disclosed for recovering high purity refractory product metal such as titanium, hafnium, zirconium, vanadium, niobium or their alloys from the regulus of a reduction reaction mixture of a by-product metal halide, excess reducing metal and product metal, which process includes feeding crushed regulus material into a furnace, heating the regulus at temperatures to melt then remove by vaporizing the metal halide and excess reducing metal, and melting the product metal before recovering it from the furnance pool obviating the steps of vacuum distillation or leaching in the recovering step.

Abstract: The process for producing crushed zirconium sponge having particle configurations which enhance its compactability, wherein conventionally produced, as-reduced, non-sintered zirconium sponge pieces are loaded into a vacuum furnace, the furnace is heated under partial vacuum at a temperature of up to about 400.degree. C. for a sufficient period to essentially demoisturize and degas the sponge, the temperature is raised to at least about 700.degree. C. and the vacuum terminated, H.sub.2 is fed in a carefully controlled manner into the furnace over a period of several hours in a total amount comprising from about 0.05 to about 0.8% by weight of the sponge, the furnace is cooled, the cooled sponge is pacified, the sponge is removed from the furnace and crushed, the crushed sponge is loaded into a vacuum furnace, the furnace is heated at from about 950.degree. C. to about 1100.degree. C.