About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Reduction Technology
|
| Presentation Title |
Magnesium Primary Production in an Aluminum Smelter |
| Author(s) |
Adam C. Powell, Nuha Abousam, Stephen Buchanan, Travis Hampton, Daniel McArthur Sehar, Kaden Ly, Demetrios Kennedy, Jared Quinn |
| On-Site Speaker (Planned) |
Adam C. Powell |
| Abstract Scope |
Direct MgO reduction in an aluminum smelter could reduce capex and time to market by 60-80% vs. a greenfield plant, while producing more magnesium than aluminum at the same current. A reactive liquid tin cathode both keeps Mg product at the cell bottom and reduces Mg activity to reduce its bath solubility, resulting in >90% current efficiency. Efficient distillation using the G-METS process recovers pure Mg, and tin returns to the electrolysis cell. This talk will focus on chemical, operational, and economic comparisons with aluminum potlines. Similarities with Hall-Héroult include operating temperature, carbon anode compatibility, raw material feeding, and exhaust handling. MgO is more effective than Al₂O₃ at scrubbing SO₂, fluorides, even PFCs from exhaust gases. MgF₂-CaF₂ is less volatile than cryolite, and compatible with zirconia as a solid oxide membrane inert anode or refractory. Thermal insulation and high cathode density can potentially enable very small anode-cathode distance, improving efficiency. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Electrometallurgy, Extraction and Processing, Magnesium |