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Molten Salt Electrolysis for Sustainable Metals Extraction and Materials Processing 17 Figure 6. Electrowinning cells for commercial magnesium production: (a) I.G. Farben cell and (b) Dow cell [32]. In the Dow process, the graphite anodes are continuously consumed for the in-situ removal of water from the cell feed to produce hydrogen and oxygen; the latter reacting with the anode. This dehydration can be summarized by reaction below: MgCl2.1.7H2O + 2C = Mg + 2HCl(g) + 2CO(g) + H2(g) (10) Due to the fact that the main anodic reaction is the evolution of chlorine, the reaction of the oxygen with the graphite does not lead to a decrease in the cell potential as in the HH cell for electrolytic reduction of Al2O3 where CO2 is the predominant anodic reaction product. Gases of CO, HCl, and H2 are detected in the anode gas, supporting the occurrence of Reaction 10. The Dow cell consumes about 0.1 kg of anode per kg Mg produced, a figure substantially higher than that of the I.G. Farben cells using anhydrous feed [33]. The power consumption for electrowinning of magnesium is 10.5-18 kWh per kg Mg. The current efficiency of the I.G. Farben cell exceeds 80 %, while that of the Dow cell is close to 80 %. The magnesium metal produced is about 99.9 % pure as it comes from the cell, since neither sodium nor calcium is reducible more easily than magnesium. The chlorine produced in the cell is converted to HCl for use in the acidification process by reaction with natural gas and steam or in a hydrogen/chlorine burner. (2) Technological Improvements to Magnesium Electrowinning Processes Research and development efforts have been directed towards fundamental studies of electrochemistry involved, improved cell designs, improved cathode conditions, and inert anodes for Dow process [3]. For example, Weert et al. explored the concept of producing HCl gas on the anode in molten salt electrowinning of magnesium to lower the cell voltage by 1 V compare toPDF Image | MOLTEN SALT ELECTROLYSIS
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