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The success of the cell feed purity project, along with extensive testing of experimental equipment, helped in the design of a new electrolyzer that was compatible with the improved MgCl2 feed. The new electrolyzer was also designed to provide: • Reduction in energy consumption of 30 percent • Productivity improvement of 300 percent • Significant reduction in labor and maintenance requirements • Improved environmental and hygiene performance • Increased ability to absorb process upsets The technical challenges of installing an advanced electrolyzer in an existing facility were met with minimal process interruption. Results High levels of impurities in the MgCl2 have been shown to have an adverse effect on the efficiency of the electrolysis process. Modifications to the MgCl2 feed preparation process resulted in significant improvement in product purity. This was accomplished with the added benefit of an overall decrease in area operating costs of 10 percent. The success of this project enabled the project team to design a high-efficiency electrolyzer for the magnesium cell rooms. The new cell design has improved and had significant impact on the MagCorp electrolysis system. • Replacing the existing electrolyzer direct-current (dc) power system with new rectifier and busbar capacity, coupled with the new electrolyzer design, has resulted in improved efficiency. Actual performance levels of 6.03 kWh/lb magnesium (including all busbars) have been demonstrated. In-cell power consumption has also decreased. • The increased scale of the new electrolyzers has provided a framework for reduced operating labor. Historically, MagCorp electrolyzers averaged 1.0 to 1.5 tons/day of magnesium, whereas the new cell design produces up to 3.1 tons/day of magnesium. This change, combined with the improved feed delivery system, has reduced area labor requirements by 83 percent. MAGCORP PROCESS FLOW CHART CaCl2 Production To Sales, Byproduct Production Cl2 HCl Selective precipitation of unwanted salts. Concentration of MgCl2 brine. Conversion of MgSO4 and removal of boron. Concentration of MGCl2 for drying. Flash drying of purified brine to specified levels of H2O and MgO. Removal of residual MgO and H2O from MgCl2. Electrical separation of MG and Cl2. Refining, alloying, and casting of all Mg products. Solar Evaporation Sulfate/Boron Removal Concentration Spray Drying MgCl2 Purification Electrolysis Casting Mg to SalesPDF Image | MINING
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