The production process mainly includes the application of magnesium reduction distillation (Kroll method) and sodium reduction distillation in industrial production. Other methods are currently in the laboratory stage, and it is expected that Kroll method will remain the main production method in the next decade. The production process of Kroll method is as follows: titanium ore-electric furnace smelting to produce high titanium slag-chlorination to produce titanium tetrachloride-refining and purification to produce refined titanium tetrachloride-magnesium reduction-distillation to produce sponge titanium-finished product crushing and packaging. If the whole production process (magnesium chloride circulation) is adopted, according to the current raw material market, the production cost per ton of sponge titanium is about 65,000 yuan.

The produced sponge titanium needs to be cast into titanium ingot (or titanium alloy) by vacuum arc furnace, and then forged or tied into corresponding tubes, plates or wires before it can be used in industry.