Techno-Economic Analysis of Magnesium Extraction from Seawater via a Catalyzed Organo-Metathetical Process

Magnesium (Mg) has many useful applications especially in the form of various Mg alloys that can decrease weight while increasing strength compared with common steels. To increase the affordability and minimize environment consequence, a novel catalyzed organo-metathetical (COMET) process was proposed to extract Mg from seawater aiming to achieve a significant reduction in total energy and production cost compared with the melting salt electrolysis method currently adapted by US Mg LLC. A process flow sheet for a reference COMET process was set up using Aspen Plus. The energy consumption, production cost, and CO2 emissions were estimated using the Aspen economic analyzer. Our results showed that it is possible to produce Mg from seawater with a production cost of $2.0/kg-Mg while consuming about 35.6 kWh/kg-Mg and releasing 7.7 kg CO2/kg-Mg. Under the simulated conditions, the reference COMET process maintains a comparable CO2 emission rate, saves about 40% in production cost, and saves about 15% in energy consumption compared with a simplified US Mg process.