Production of Magnesium and Aluminum-Magnesium Alloys from Recycled Secondary Aluminum Scrap Melts

An experimental proof of concept was demonstrated for a patent-pending and trademark-pending RE12(TM) process for extracting a desired amount of Mg from recycled scrap secondary Al melts. Mg was extracted by electrorefining, producing a Mg product suitable as a Mg alloying hardener additive to primary- grade Al alloys. This efficient electrorefining process operates at high current efficiency, high Mg recovery and low energy consumption. The Mg electrorefining product can meet all the impurity specifications with subsequent melt treatment for removing alkali contaminants. All technical results obtained in the RE12(TM) project indicate that the electrorefining process for extraction of Mg from Al melt is technically feasible. A techno-economic analysis indicates high potential profitability for applications in Al foundry alloys as well as beverage-can and automotive-sheet alloys. The combination of technical feasibility and potential market profitability completes a successful proof of concept. This economical, environmentally-friendly and chlorine-free RE12(TM) process could be disruptive and transformational for the Mg production industry by enabling the recycling of 30,000 tonnes of primary-quality Mg annually.