Abstract: The conversion of oxides into metals is one of the key steps in the dry reprocessing of spent oxide fuel using the molten salt electrorefining method. In this study, in the CaCl₂-NaCl molten salt system, graphite rods were used as anodes, and the high-temperature sintered ZrO₂ flakes were simulated UO₂ cathode. Besides, the FFC Cambridge process conditions of electro-deoxidation to prepare metal zirconium in CaCl₂-NaCl molten salt were optimized. The effects of electrolysis process conditions(cell voltage, electrolysis time, sintering temperature, and electrolysis temperature, etc.) on the preparation of Zr by electro-deoxidation was studied systematically. SEM and XRD were utilized to analyze the microstructure and phase composition of the ZrO₂ cathode before and after electrolysis, respectively. The optimized process conditions are voltage of 3.4 V, electrolysis time of 12 h, sintering temperature of 900 ℃, and electrolysis temperature of 722 ℃. At the same time, the intermediate products CaZrO₃ and ZrO are found in the conversion of ZrO₂ into Zr.