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

STTR 第二阶段：通过碳热还原连续生产和收集镁

• 批准号: 1738536
• 负责人: Aaron Palumbo
• 金额: $ 70万
• 依托单位: Big Blue Technologies LLC
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2017
• 资助国家: 美国
• 起止时间: 2017-09-15 至 2022-05-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1738536&HistoricalAwards=false
• 关键词: STTR; Phase; II; Continuous; Production

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.

这个小企业技术转让研究（STTR）第二阶段项目的更广泛的影响/商业潜力源于解决用于车辆轻量化的镁金属制造中的嵌入式能源问题。通过加入最轻的结构金属镁来提高燃料经济性，如果使用传统方法生产镁，则不会节省总生命周期消耗的能量。已知的最节能和最经济的生产方法是在第二次世界大战期间商业上可行的工艺技术，但在历史上的任何其他时间都不可行。项目创新重新调查和改造这个过时的过程，发现技术和经济失败的原因。采用最先进的节能实践的国内镁生产将为下游制造商带来机会和增长，这些制造商支持广泛的军事，工业和消费品，如汽车零部件，电子设备，钛和钢铁生产以及罐装饮料。鉴于过去100年来镁金属的使用量空前增加，这项创新的长期经济和环境效益将更具先见之明。这一创新为镁生产创造了一条清洁经济的路线，有助于重振美国的轻金属工业。该项目的智力价值来自于碳热还原氧化镁产生的镁金属气体冷凝的新范式。以前，采用通过亚稳定温度范围的冲击冷却，产生危险且难以处理的自燃粉末。该第二阶段研究使用快速冷却和受控非均相冷凝来形成坚固的抗氧化镁冷凝物。该工艺在新型连续冷凝器中进行，以获得高金属产量。这一努力也通过开发还原反应器技术而成为可能，该技术在比以前使用的更温和的条件下操作，同时保持高生产率。工厂的总能耗将比占主导地位的现有工艺至少低50%。第二阶段项目将形成一个规模化的矿石到铸锭试验设施，用于将镁金属作为原材料制造到制造过程中。产品质量、工艺可行性和经证实的放大将得到证明。

项目成果

Design and Fabrication of Pellets for Magnesium Production by Carbothermal Reduction

• DOI: 10.1007/s11663-018-1309-5
• 发表时间: 2018-06
• 期刊: Metallurgical and Materials Transactions B
• 作者: B. Chubukov;A. W. Palumbo;Scott C. Rowe;Mark A. Wallace;K. Y. Sun;A. Weimer

Investigation of continuous carbothermal reduction of magnesia by magnesium vapor condensation onto a moving bed of solid particles

• DOI: 10.1016/j.powtec.2019.01.067
• 发表时间: 2020-04-01
• 期刊: POWDER TECHNOLOGY
• 影响因子: 5.2
• 作者: Chubukov, Boris A.;Rowe, Scott C.;Weimer, Alan W.
• 通讯作者: Weimer, Alan W.