Process for magnesium metal extraction from mineral sources

A metal extraction process comprising:

• a) preparing a homogeneous admixture of metal oxide powder, reducing agent powder, and catalyst powder;
• b) pelletizing the admixture to yield a plurality of pellets;
• c) positioning the plurality of pellets in a cartridge;
• d) positioning the cartridge in a reducing chamber;
• e) heating the reducing chamber to a reducing temperature;
• f) pulling a partial vacuum in the reducing chamber;
• g) vaporizing desired metal from the plurality of pellets;
• h) condensing vaporized metal on a condensation surface positioned in a condensation chamber in pneumatic communication with the reducing chamber;
• i) cooling the condensation surface outside the condensation chamber;
• j) removing condensed metal bodies from the condensation surface;
• k) introducing condensed metal bodies into a smelting furnace;
• l) introducing a nonoxidizing cover atmosphere into the smelting furnace;
• and
• m) melting the condensed metal bodies into metal ingots;
• wherein the cover atmosphere is at least eighty percent carbon dioxide with the remainder selected from the group consisting of nitrogen, Novac 612, sulfur dioxide, HFC-134a, HFC-7100, and combinations thereof.