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Kroll process
The processing of titanium metal occurs in four major steps: reduction of titanium ore into "sponge", a porous form; melting of sponge, or sponge plus a master alloy to form an ingot; primary fabrication, where an ingot is converted into general mill products such as billet, bar, plate, sheet, strip, and tube; and secondary fabrication of finished shapes from mill products.

Because it cannot be readily produced by reduction of titanium dioxide, titanium metal is obtained by reduction of titanium tetrachloride (TiCl4) with magnesium metal in the Kroll process. The complexity of this batch production in the Kroll process explains the relatively high market value of titanium, despite the Kroll process being less expensive than the Hunter process. To produce the TiCl4 required by the Kroll process, the dioxide is subjected to carbothermic reduction in the presence of chlorine. In this process, the chlorine gas is passed over a red-hot mixture of rutile or ilmenite in the presence of carbon. After extensive purification by fractional distillation, the TiCl4 is reduced with 800 C molten magnesium in an argon atmosphere.