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MINING BestPractices Technical Case Study August 2001 OFFICE OF INDUSTRIAL TECHNOLOGIES ENERGY EFFICIENCY AND RENEWABLE ENERGY, U.S. DEPARTMENT OF ENERGY BENEFITS • Improves process efficiency • Reduces energy consumption • Reduces labor requirements by up to 83 percent • Increases productivity • Reduces maintenance costs by up to 60 percent • Reduces emissions APPLICATIONS Older electrolytic reduction processes often have elevated labor and energy expenses and increased environmental losses of chlorine. Application of updated technologies can help reduce levels of oxygen, iron, and carbon in the cell feed while reducing energy consumption, eliminating excessive chlorine losses, and reducing the operating labor required. Modernization of Electrolysis System at MagCorp Reduces Costs and Waste Summary Magnesium Corporation of America (MagCorp) has undertaken a modernization program at its Utah magnesium production facility. The modernization program is designed to improve the performance efficiency of the plant’s electrolysis system and eliminate chlorine losses. The modernization program has resulted in operating benefits, including significant reduction in labor, energy, and maintenance costs, as well as reducing process waste emissions. Plant/Company Overview MagCorp (formerly Amax) is the oldest primary magnesium producer in the United States; the company has provided high-quality magnesium metal ingots to the world market since 1972. Headquartered on Utah's Great Salt Lake, MagCorp manufactures magnesium metal and its alloys for a variety of end-use applications. Using primary solar energy, the natural brine of the Great Salt Lake is concentrated, purified, and dried into magnesium chloride (MgCl2) powder. The powder is melted and introduced into electrolytic reduction cells to produce pure magnesium metal. Producing magnesium metal historically has been successful because of its low cost and the flexibility of the casting system. The primary disadvantage of the process has been the use of older electrolysis technology, which leads to elevated labor and energy expenses. Older electrolyzers also cause increased loss of chlorine to the environment. Project Overview To improve the MgCl2 cell-feed purity and electrolyzer performance, MagCorp initiated two separate upgrade projects during the 1990s. A feed purity improvement project was directed toward cost-effective reduction in levels of oxygen, iron, and carbon in the MgCl2 cell feed. The electrolysis improvement project was aimed at reducing energy consumption, eliminating excessive chlorine losses, and reducing the operating labor required. Project Implementation Cell-feed purification project. Electrolytic production of magnesium can be simplified into two primary steps: preparing MgCl2 powder, and the subsequent electrolysis of the salt. Electrolyzers must be designed to handle the specific chemical compositions resulting from the feed preparation step. MagCorp historically averagedPDF Image | MINING
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