Abstract: A process for producing titanium metal sponge from an exothermic reaction between titanium tetrachloride vapor and molten magnesium vapor, and reclaiming reactive metals from by-products of the exothermic reaction.

Abstract: In this invention, the smelting reduction operation can be carried out in a high efficiency by charging a carbonaceous material in such an amount that total surface area is not less than 60 m.sup.2 per 1 ton of slag weight. Carbon substance finely particulating through thermal crumbling under a high-temperature atmosphere inside the vessel is used as the carbonaceous material, whereby it is possible to stably conduct the smelting reduction while controlling the scattering of the carbonaceous material, and also the erosion, particularly locally erosion of refractory in the smelting reduction furnace, which was a serious problem in the conventional technique, can considerably be decreased to largely prolong the service life of refractory.

Abstract: A molybdneum, rhenium, and tungsten alloy having an improved erosion, ductility, strength and a higher recrystallization temperature. The alloy may be fabricated into equipment which is useful for manufacturing chemicals such as a hydrochlorofluorocarbon.

Abstract: A zirconium sponge regulus from a Kroll reduction process is contaminated with zirconium chlorides, unreacted magnesium and magnesium chloride. The sponge regulus is vacuum distilled at a temperature of at least 800.degree. C. and then cooled. Before opening the distillation vessel and exposing the sponge regulus to the atmosphere, the vessel is backfilled with a gas comprising 25% to 75%, by volume, carbon dioxide, carbon monoxide or mixtures thereof, with the balance an inert gas and impurities associated therewith.The sponge regulus is less susceptible to fires when exposed to the air or crushing in downstream processing, and the metal surfaces of the sponge regulus are passivated whereby the overall contamination of the sponge is significantly reduced.

Abstract: A vacuum distillation furnace and method for removing unreacted magnesium metal and magnesium chloride from a sponge refractory metal, such as zirconium, utilizes a vertically arranged series of mutually isolated distillation vessels in respective furnace sections for continuous or semi-continuous vacuum distillation of the sponge metal following formation thereof by usual reduction procedures.

Abstract: A sponge refractory metal product, especially a zirconium metal sponge, that retains a residual quantity of magnesium chloride following subjection to an initial, conventional, distillation cycle is reprocessed by the addition of virgin magnesium in amount normally within the range of about 20% to about 60% of the weight of such sponge metal product and by passing it through re-distillation, including the steps of melting the added virgin magnesium and the sponge metal to open the otherwise closed pores thereof, lowering furnace temperature to solidify the molten magnesium, raising the temperature to vaporize and remove from the furnace the magnesium metal, and again raising the temperature to vaporize and remove from the furnace the initially entrapped magnesium chloride. Thereafter, it is preferable that the temperature be again raised to sinter together any loose particles of the sponge metal. It is believed that a eutectic of the sponge metal is formed during the process.