Abstract
The electrolysis of 
in an electrolyte of 
to produce ductile zirconium metal has been expanded from the laboratory scale into a larger scale operation. An electrolytic cell capable of producing 3–4 lb of zirconium metal per run was designed and operated. Following successful operation of this unit, a cell capable of producing 30–40 lb of zirconium metal per run was used to evaluate the process on a scale 50 to 60 times the laboratory scale.
Electrolytic zirconium powder of high purity has been reproducibly obtained in good yields and at commercially acceptable current efficiencies. Upon consolidation, the metal shows fabricating properties comparable to those exhibited by Kroll sponge zirconium. The present larger electrolytic cell produces zirconium metal at a rate approaching that of the original commercial Kroll sponge producing reactors. Further expansion to larger scale operation should be entirely feasible.