STTR Phase II: Continuous Production and Collection of Magnesium via Carbothermal Reduction

The broader impact/commercial potential of this Small Business Technology Transfer Research (STTR) Phase II project stems from addressing the problem of embedded energy in the manufacture of magnesium metal for use in vehicle light-weighting. Improving fuel economy by incorporation of the lightest structural metal, magnesium, does not save on total lifecycle energy consumed if the magnesium was produced using conventional methods. The most energy efficient and economical production method is known is a process technology that was commercially viable during World War II but not at any other time in history. The project innovation reinvestigates and reinvents this dated process, discovering the reasons for technical and economic failure. Domestic magnesium production using state-of-the-art energy-efficient practices will lead to opportunity and growth for downstream manufacturers that support a wide range of military, industrial, and consumer products such as car parts, electronic devices, titanium and steel production, and canned beverages. The economic and environmental benefits of the innovation in the long term will be ever more prescient given the unprecedented rise in use of magnesium metal over the past 100 years. This innovation creates a clean and economic route to magnesium production, helping to reinvigorate light metals industries within the U.S. The intellectual merit of this project is derived from a new paradigm in the condensation of magnesium metal gas produced by carbothermal reduction of magnesium oxide. Previously, shock cooling through a meta-stable temperature range was employed, generating pyrophoric powders that are dangerous and difficult to handle. This Phase II research uses both rapid cooling and controlled heterogeneous condensation for the formation of robust, oxidation resistance magnesium condensate. This process is executed in a novel and continuous condenser for high metal throughput. This effort is also made possible through the development of a reduction reactor technology that operates under milder conditions than previously used while maintaining high production rates. Total plant energy consumption will be at least 50% less than the dominant incumbent process. The Phase II project will result in a scaled ore-to-ingot pilot facility for the manufacture of magnesium metal as a raw material into manufacturing processes. Product quality, process feasibility, and proven scale-up will be demonstrated.