Continuous Magnesium Vacuum Distillation System for High-Purity Metal Recovery
Client Objective
A specialty materials manufacturer required a continuous vacuum distillation system capable of separating and purifying magnesium and magnesium-based alloys under high-vacuum, high-temperature conditions. The system needed to handle continuous operation, support multiple distillation zones, and achieve ultra-high purity levels for magnesium used in aerospace, defense, battery, and electronics applications.
Our Solution: A First-of-its-Kind Pressure Cycling System
Ants Innovations designed and commissioned a modular, continuous-operation Magnesium Vacuum Distillation Furnace, engineered to work efficiently at temperatures up to 1200°C and vacuum levels of 10⁻³ to 10⁻⁵ mbar. The system allows simultaneous melting, evaporation, and condensation, making it suitable for both refining and alloy separation processes.
High-Temperature & Vacuum Capability
- Operating range: 900°C to 1200°C
- Vacuum level: 10⁻³ to 10⁻⁵ mbar for optimal distillation of magnesium
- High-efficiency heating system integrated with PID control for precision
Chamber & Mechanical Design
- Constructed from nickel-based alloys or high-grade SS to withstand extreme thermal stress and corrosion
- Modular structure supports continuous feed and discharge for uninterrupted operation
- Multi-zone temperature control for independent heating of melting, evaporation, and condensation stages
Distillation & Recovery Efficiency
- Vaporized magnesium is directed to a dedicated condensation zone where it is collected in solid form, minimizing losses
- Custom-designed condenser ensures high-purity recovery of magnesium metal from raw or alloyed feedstocks
Inert Gas Integration
- Supports argon or nitrogen backfilling to prevent oxidation during cooling or unloading phases
- Maintains safety and metal integrity during all stages of the distillation cycle
Instrumentation & Control
- Digital pressure gauges and vacuum sensors for real-time monitoring
- PLC-based PID temperature controllers ensure stable operations
- Configurable data logging and alarm systems for safe, unattended operation
Continuous Feed System
- Designed for continuous charging and distillation column operation
- Supports industrial production without batch interruptions, reducing downtime and improving throughput
High-Purity Magnesium Production
Enabled efficient removal of impurities like calcium, aluminum, and zinc from recycled or raw magnesium, ensuring electronic- and aerospace-grade purity.
Alloy Separation and Recovery
The system's fine control over evaporation parameters allowed selective distillation of magnesium from magnesium-aluminum and magnesium-zinc alloys, enabling recovery of valuable base elements.
Advanced Materials
R&D
Provided researchers with a robust platform for studying magnesium thermodynamics, phase transitions, and vacuum behavior, further supporting battery material development and lightweight metal innovations.
Industrial
Versatility
With its customizable layout and modular design, the system is now positioned to scale from laboratory R&D to full-scale metal recovery plants, supporting industries from automotive to defense.
High-Purity Magnesium Production
Enabled efficient removal of impurities like calcium, aluminum, and zinc from recycled or raw magnesium, ensuring electronic- and aerospace-grade purity.
Alloy Separation and Recovery
The system's fine control over evaporation parameters allowed selective distillation of magnesium from magnesium-aluminum and magnesium-zinc alloys, enabling recovery of valuable base elements.
Advanced Materials
R&D
Provided researchers with a robust platform for studying magnesium thermodynamics, phase transitions, and vacuum behavior, further supporting battery material development and lightweight metal innovations.
Industrial
Versatility
With its customizable layout and modular design, the system is now positioned to scale from laboratory R&D to full-scale metal recovery plants, supporting industries from automotive to defense.
Outcome
The delivered solution not only exceeded purity and performance targets but also positioned the client at the forefront of sustainable, high-performance magnesium processing. With enhanced recovery efficiency, continuous production capacity, and process control, the system has become central to their clean metallurgy and recycling initiatives.
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