Advances in innovative magnesium smelting technology and innovations in the Pidgeon process

To address the challenges of high carbon emissions, low energy efficiency, and limited automation in the Pidgeon process using horizontal retort, this study proposes region-specific innovation strategies. For semi-coke-rich regions (e.g., Yulin, Shaanxi, which contributes more than 50% of magnesium production), a synergistic system integrating exhaust purification, waste heat power generation, and corrosion-resistant retorts has been developed. Through cascaded waste heat utilization (reducing energy consumption to 3.2 tons of standard coal per ton of Mg) and CO₂ capture (with a recovery ratio exceeding 85%), this system achieves enhanced energy efficiency and carbon reduction. For renewable energy-abundant regions, a high-frequency induction heating process powered by green electricity (with a thermal efficiency of over 75%) is designed, along with intelligent temperature control technology (with a fluctuation of ±5 ℃). Coupled with a multi-energy complementary power supply (green electricity terminal price ≤0.2 CNY/kWh), this approach reduces carbon emissions by 90% per ton of magnesium. Research indicates that emerging technologies (e.g., duplex vertical furnaces, electric internal heating methods) demonstrate superior laboratory performance, but they face scalability challenges, including short equipment lifespans and high material costs. Therefore, incremental improvements to the Pidgeon process using horizontal retort should be prioritized to provide regionally adaptable pathways for the industry's low-carbon transition.