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0.70 percent non-electrolyte impurities, which is significantly higher than the 0.20 percent maximum designed for most high-efficiency electrolyzers. The project objective was to significantly reduce impurity with minimal changes in infrastructure. The existing chlorination system used refractory-lined cells arranged in a primary and secondary process scheme. These units used chlorine sparging tubes to introduce gas into the reactors. Process kinetics were driven by reactant control, reactant contact (control of chlorine vapor bubble size), residence time, and mixing. After extensive experimentation, a tertiary chlorination step was added to the existing system. This modification involved installation of a proprietary vertical chlorinator for removal of residual oxygen and iron. Additional modifications included installation of an electronic control scheme for reactant, power, and gas handling. Chlorinators were modified to eliminate air introduction into the reactors and to accept a vertical electrode design that improved the refractory layout. These modifications dramatically improved reliability, cleanliness, and control of the system. Other equipment modifications included installation of additional product surge capacity and new mobile feed-hauling equipment for MgCl2 transport to the cell rooms. These modifications resulted in a substantial reduction in the introduction of MgCl2 impurities through handling. Electrolysis improvement project. Because of the labor, energy, and maintenance expenses associated with the equipment, magnesium electrolysis is the most cost-intensive processing step in the electrolytic method of production. Historically, MagCorp used both diaphragm and diaphragmless electrolyzer designs. Although the diaphragmless designs enjoy the benefits of increased productivity and improved chlorine collection capability, both types of electrolyzers suffer from an excess labor burden, unfavorable chlorine recovery, and limited unit productivity. TERTIARY VERTICAL CHLORINATORPDF Image | MINING
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