Review on Electrolytic Processes for Magnesium Metal Production: Industrial and Innovative Processes

Magnesium (Mg) metal is an attractive material for various industries due to its superior properties. Currently, the Pidgeon process is commercially used for primary Mg metal production. However, due to its high carbon dioxide (CO2) gas emissions, electrolytic processes have attracted attention in recent years. Industrial electrolytic processes that use anhydrous magnesium chloride (MgCl2) feedstock have a lower impact on global warming. Unfortunately, toxic chlorine (Cl2) gas is generated during metal production, and anhydrous MgCl2 production is energy intensive. In response, efforts have been made to improve industrial electrolytic processes and develop new electrolytic processes. Among these processes, the electrolysis of magnesium oxide (MgO) in molten fluoride salt is currently considered a promising alternative for the environmentally sustainable production of Mg metal with the generation of oxygen (O2) gas. This paper comprehensively reviews industrial and innovative electrolytic processes, aiming to propose the next-generation Mg metal production method.