The development of efficient and environmentally friendly technological processes for processing zircon concentrate is an urgent problem in the technology of producing reactor-pure zirconium and hafnium used in nuclear power. The review presents the environmental, technical and economic characteristics of zircon decomposition processes using existing industrial technologies and provides data on the environmental safety of each technology. It is shown that current industrial technologies do not meet the criteria of sustainable development and allow emissions of toxic reagents into the environment. New applications of particularly pure zirconium and hafnium compounds which have emerged in recent decades, with impurity content of 10-3–10-5%, require less corrosive reagents than chlorine and fluorine, new resource-saving processes and equipment. Today, technical zirconium oxide with a purity of 98% is the main industrial product of zircon processing, but it allows for losses of hafnium, scandium and silicon. This is equivalent to financial losses of over USD 150 million per year. Based on the analysis of promising halogen-free technologies, a new integrated zircon processing technology is proposed which allows producing scarce hafnium, scandium and silicon compounds along with reactor-pure zirconium and its high-purity chemical compounds. The chemicals consumed in the zircon processing process are utilized in the production of mineral fertilizers, eliminating environmental pollution. The use of the highly efficient refining extraction process in a nitric acid environment using centrifugal extractors with an available tributilphosphate extractant allows us to obtain reactor metals with a purity of 99.95%. The production of high-purity zirconium, hafnium, scandium and silicon oxides meets the demand for non-nuclear products, which expands the volume of integrated zircon processing and meets the growing market demand for new functional materials. The integrated approach to zircon processing can reduce the cost of zircon by producing by-products, recycling consumed reagents and eliminating non-recyclable solid and liquid waste. This will ensure environmental protection even with relatively small volumes of reactor-pure metal production.
