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In this study, we examined the effect of potassium perchlorate (KClO 4 ) and magnesium hydroxide (Mg(OH) 2 ) additives on the combustion behavior of a ZrO 2  + 2Mg mixture to produce a fine powder of zirconium metal. The results of thermodynamic analysis and experiments imply that nearly 0.04 mol of KClO 4 is needed to initiate a combustion reaction in the ZrO 2  + 2Mg system. As the amount of KClO 4 increases from 0.04 to 0.1 mol, the combustion temperature increases from 1250 to 1850 °C. This results in formation of fine zirconium powder with a typical particle size of less than 5 µm, and with 1.4–2.2 wt% residual oxygen. Subsequent reduction of particle size to 100–500 nm, and oxygen content to <1.0 wt% was achieved by adding Mg(OH) 2 . The as-prepared Zr powder was mixed with nitrocellulose and printed onto 10–100 µm thin-layers to study their burning stability. The wave propagation in a thin layer was on the order of 0.35–30 cm/s, which is suitable for applications requiring localized power generation. [ABSTRACT FROM AUTHOR]