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<p>This work presents a comprehensive study on the sustainable production of metallic magnesium from high purity dolomite ore. The process of chain optimization included calcination-hydration, Ca–Mg separation, and vacuum aluminothermic reduction stages. Optimum calcination was achieved at 1100&#xa0;°C for 60&#xa0;min, providing the highest hydration activity (36.78%) through complete dolomite decomposition. A three-step Ca–Mg separation process comprising digestion, carbonization, and crystallization enabled the selective recovery of high-purity MgO and fine particles of CaCO<sub>3</sub> fractions. The effects of raw material particle size, CO<sub>2</sub> flow rate, and solid/liquid ratio were systematically investigated, and an additional washing step reduced MgO contamination in the CaCO<sub>3</sub> phase to 2.37 wt.%. The obtained MgO was further used for aluminothermic reduction under vacuum at 1300&#xa0;°C for 9&#xa0;h. Increasing aluminum stoichiometry (75–122% of the theoretical value) enhanced magnesium recovery from 75.05% to 97.70%, while the MgO content in the residue decreased from 26.97 to 2.35%. X-ray diffraction (XRD) analyses revealed high-purity metallic magnesium (magnesium crown) along with Al<sub>2</sub>O<sub>3</sub> and MgAl<sub>2</sub>O<sub>4</sub> spinel in the residue. In addition, the water-based resulting solutions within the Ca–Mg separation scheme are recyclable within the process chain, establishing a waste minimization, closed-loop approach. The results confirm that this integrated hydrometallurgical–pyrometallurgical route offers an efficient alternative to conventional magnesium metal production, with the potential for reduced emissions and improved waste minimization.</p> Graphical Abstract <p></p>

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Waste Minimization Approach in the Vacuum Aluminothermic Production of Green Magnesium via CaO–MgO Separation

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年6月18日

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  • Kagan Benzesik,
  • Çağdaş Ekin Zöhra,
  • Ilhan Göknel,
  • Onuralp Yücel

摘要

This work presents a comprehensive study on the sustainable production of metallic magnesium from high purity dolomite ore. The process of chain optimization included calcination-hydration, Ca–Mg separation, and vacuum aluminothermic reduction stages. Optimum calcination was achieved at 1100 °C for 60 min, providing the highest hydration activity (36.78%) through complete dolomite decomposition. A three-step Ca–Mg separation process comprising digestion, carbonization, and crystallization enabled the selective recovery of high-purity MgO and fine particles of CaCO3 fractions. The effects of raw material particle size, CO2 flow rate, and solid/liquid ratio were systematically investigated, and an additional washing step reduced MgO contamination in the CaCO3 phase to 2.37 wt.%. The obtained MgO was further used for aluminothermic reduction under vacuum at 1300 °C for 9 h. Increasing aluminum stoichiometry (75–122% of the theoretical value) enhanced magnesium recovery from 75.05% to 97.70%, while the MgO content in the residue decreased from 26.97 to 2.35%. X-ray diffraction (XRD) analyses revealed high-purity metallic magnesium (magnesium crown) along with Al2O3 and MgAl2O4 spinel in the residue. In addition, the water-based resulting solutions within the Ca–Mg separation scheme are recyclable within the process chain, establishing a waste minimization, closed-loop approach. The results confirm that this integrated hydrometallurgical–pyrometallurgical route offers an efficient alternative to conventional magnesium metal production, with the potential for reduced emissions and improved waste minimization.

Graphical Abstract