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• Maintenance costs of the new electrolyzer system are dramatically improved from those of older designs because of the ruggedness, simplicity, and improved electrode cooling of the new system. Maintenance requirements have been reduced by 60 percent. “Rebuild” expenses have also decreased. • Emissions have been significantly reduced. Worker exposures to chlorine and thermal emissions have been reduced by 45 percent and 30 percent, respectively. Collection of chlorine has been significantly improved, with more than 99.9 percent capture because of the proprietary metal collection system. Lessons Learned Modernization of the MagCorp electrolysis system has demonstrated that it is technically and economically feasible to retrofit existing production facilities with equipment that provides world-class performance. The installed cost of the feed purification system and electrolysis equipment upgrades was approximately $1,100/ton of annual magnesium production. This approach to performance improvement can provide older magnesium producers with the efficiencies required to compete in the high-quality magnesium market with reasonable rates of return on facility investments. The technological approach can also provide the framework for significant volume expansions should market growth require future increases. BestPractices is part of the Office of Industrial Technologies’ (OIT’s) Industries of the Future strategy, which helps the country’s most energy-intensive industries improve their competitiveness. BestPractices brings together the best- available and emerging technologies and practices to help companies begin improving energy efficiency, environmental performance, and productivity right now. BestPractices focuses on plant systems, where significant efficiency improvements and savings can be achieved. Industry gains easy access to near-term and long-term solutions for improving the performance of motor, steam, compressed air, and process heating systems. In addition, the Industrial Assessment Centers provide comprehensive industrial energy evaluations to small- and medium-size manufacturers. PROJECT PARTNERS Magnesium Corporation of America (MagCorp) Salt Lake City, UT FOR ADDITIONAL INFORMATION, PLEASE CONTACT: OIT Clearinghouse Phone: (800) 862-2086 Fax: (360) 586-8303 clearinghouse@ee.doe.gov Visit our home page at www.oit.doe.gov Please send any comments, questions, or suggestions to webmaster.oit@ee.doe.gov Office of Industrial Technologies Energy Efficiency and Renewable Energy U.S. Department of Energy Washington, DC 20585-0121 DOE/GO-102001-1374 August 2001 Industry of the Future—Mining In mid-1998, the National Mining Association reached an agreement with the U.S. Department of Energy’s Industries of the Future Program to join in creating research and development partnerships to develop and deploy new technologies that will improve environmental performance and enable the industry to meet increased global competition. The mining industry supplies the minerals and coal essential to the infrastructure of virtually the entire U.S. economy: glass, ceramics, metals; cement for buildings, bridges, roads, and equipment; and coal or uranium to generate more than 70% of the nation’s electricity. OIT Mining Industry Team Leader: Michael Canty (202) 586-8119.PDF Image | MINING
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