The main aims of this research were to modify and optimize the process of zirconium-chloride production in continuous and semi-batch modes and to change the current fixed-bed reactor into an electro thermal fluidized bed one. Thus, after modeling process, a pilot scale electro thermal fluidized bed reactor with the capacity of 10 kg/day of Zirconium tetrachloride was designed and fabricated. To increase the interaction surface between the carbon and zirconia, a unique method was applied in which the two components were mixed at first and then it shaped pasty by adding sucrose and water, after that by compression in Briquetting Machine it converted to granules with a few centimeters size. The obtained briquettes were heated and reground to the desired particles sizes. Utilizing the produced powder in the pilot reactor, Zirconium Tetrachloride was produced in various conditions. The results were consistent with the modeling outputs. Also the optimization of effective parameters was implemented through the Response Surface Methodology (RSM). The experiments were designed and conducted for each modes mentioning the most effective parameters which are as the following: for semi-batch mode, Temperature (800-1200 o C), Time (10-90 min), particles average size (70-130 µm) and for continuous mode temperature (1000-1400 o C), chlorine gas concentration to reactor (3-5 mol/m 3 ) and particles average size (70-130 µm). The RSM results showed that the experimental data are in consistent with the second degree polynomial model. In addition, it was shown that the two parameters of time and temperature in the semi-batch mode and the all of three parameters of chlorine concentration, temperature and time in the continuous mode were highly effective. The recognition coefficient (R 2 ) for semi-batch and continuous modes were 99.54 and 99.94 respectively. The optimized process condition achieved by RSM are as the following: for the continuous mode the chlorine concentration of 3 mol/m 3 , the temperature of 1380 o C and the average particle size of 70 microns leaded to maximum conversion percentage of zirconia which was 98.26% and similarly for the semi-batch mode the temperature of 1200 o C, the average particle size of 70 microns and reaction time of 90 minutes resulted in maximum conversion percentage of zirconia that was 92.7%. using this innovative method for production of reactor powder feed and utilizing the recycled materials from another zirconia production process, we could increase the reaction rate and process efficiency up to 14%, and also the energy consumption was reduced significantly. Keywords: Fluidized bed reactor, Zirconia, Zirconium dioxide, Zirconium tetrachloride, optimization