Pidgeon Process Magnesium Metal Production Line with Reduction Furnace Smelting Plant

Product Description

Product Description

Metal magnesium, magnesium carbonate, magnesium oxide, production line

This full-automatic magnesium oxide production line is a professional turnkey calcination plant for producing industrial and high-purity MgO powder. It supports two mature technologies: mineral calcination method (magnesite/dolomite) and brine chemical method.

 

The whole line integrates crushing, grinding, drying, preheating, high-temperature calcination, cooling, powder classification and environmental protection treatment. With precise PLC temperature control, it ensures stable MgO activity and purity. Waste heat recovery system reduces energy consumption by 25%-35%. Fully closed negative pressure design meets EU environmental standards, no dust pollution and no export barriers.

 

Our production line can produce multi-grade MgO, including desulfurization-grade, refractory-grade, high-purity and nano magnesium oxide, widely used in metallurgy, environmental protection, rubber, construction and chemical industries..

Technical Parameter Selection Table
Model 1: Small Capacity 500 to1000kg/h
Annual Output: 1000 to 3000 tons MgO
Kiln Size: Φ1.2*12m Rotary Kiln
Total Power: 185KW
Floor Space: 32m*12m
Suitable: Small factory, feed grade, light industrial MgO
Model 2: Medium Capacity 2 to 5t/h
Annual Output: 6000 to15000 tons MgO
Kiln Size: Φ1.6×18m Rotary Kiln
Total Power: 380KW
Floor Space: 45m*16m
Suitable: Comprehensive production line, multi-grade MgO switching
Model 3: Large Capacity 8 to 20t/h
Annual Output: 25000 to 60000 tons MgO
Kiln Size: Φ2.4×28m Rotary Kiln
Total Power: 750 to1200KW
Floor Space: 65m*22m
Suitable: Large magnesite mine, refractory high-purity MgO mass production

Production capacity: 6,000 tons/year - 200,000 tons/year 
Specification: Φ1.6x32m - Φ5.1×72m 
Fuel: natural gas, gas, pulverized coal, etc.

The process flow
The process flow selection for magnesium metal smelting adopts the mature, reliable and reasonable new Pidgeon process for magnesium smelting. It includes raw material storage, dolomite calcination, powder grinding and pelletizing, reduction and refining sections.

1.Limestone calcination process (main ore route)
Raw Ore → Crushing & Screening → Raw Material Storage → Drying → Multi-stage Preheating → High Temperature Calcination Kiln → Cooling → Grinding Mill → Air Classification → Dust Collection → Automatic Packaging → Finished MgO Warehouse

* Crushing and screening: Crush the large pieces of magnesite to uniform particles of 3-10mm, remove impurities
* Drying: Dried with residual heat, reducing the moisture content of the raw materials to ≤1%
* Multi-stage preheating: Preheat the raw materials with the residual heat from the calcination exhaust gas, saving energy and reducing consumption
* High-temperature calcination: Controlled temperature ranging from 550 to 1450ºC, decomposing magnesium carbonate to generate magnesium oxide
* Cooling: Water cooling / Air cooling in a sealed environment, preventing moisture absorption and re-alkalization
* Ultra-fine grinding and classification: The fineness can be adjusted from 200 to 3000 mesh
* Dust removal and recovery: Two-stage dust removal using a cyclone and bag filter, powder recovery rate ≥ 99.9%
* Automatic packaging: Automatic filling and sealing of 25kg/50kg/1 ton bags

2.Brine / Magnesium hydroxide high-purity magnesium oxide process (for high-end food and pharmaceutical grades)
Brine Purification → Precipitation of Magnesium Hydroxide → Filter Press → Flash Drying → High-temperature Calcination → Ultrafine Grinding → Iron Removal Screening → Dust Recovery → Sterile Packaging
Suitable for producing high-purity magnesium oxide with a purity of over 99.5%, meeting the FCC/USP food and pharmaceutical standards for heavy metal content.

3.Main Equipment List

• Raw Material Crushing System: Jaw Crusher, Hammer Mill, Vibrating Screen, Belt Conveyor
• Drying & Preheating Equipment: Rotary Dryer, Waste Heat Preheater, Hot Air Furnace
• Core Calcination Host: Rotary Kiln / Flash Cyclone Calciner (custom size Φ1.2×12m ~ Φ3×30m)
• Cooling System: Rotary Cooler, Sealed Air Cooling Machine
• Grinding & Classifying Unit: Vertical Mill / Ball Mill, Air Classifier
• Dust Removal System: Cyclone Separator + Pulse Bag Dust Collector + Waste Gas Washing Tower
• Automatic Feeding & Mixing: Screw Conveyor, Weighing Feeder, Stirring Tank
• Packaging System: Automatic Powder Packing Machine, Ton Bag Filling Equipment
• Central Control Cabinet: PLC Touch Screen, Remote Monitoring Module, Temperature Sensor

Raw material reserves 

The dolomite is crushed in the mine to the required particle size and then stored in the dolomite storage yard on the factory premises. Silicon iron and fluorspar are directly stored in the factory warehouses. The reserves are all calculated based on the usage amount for half a month of production. 

Limestone calcination workshop 

An energy-saving and environmentally-friendly rotary kiln is selected, along with a vertical preheater and a vertical cooler. The dolomite with the required particle size and quality is unloaded to the storage area. The loading machine is used for loading and unloading operations, and the vibrating screen is used for screening. Then, the dolomite with a particle size of 10-40mm is transported by belt to the top storage bin of the vertical preheater of the rotary kiln. It enters the preheater through a pipe and exchanges heat with the high-temperature flue gas flowing from the rotary kiln, preheating the material to above 800ºC. After falling into the transfer chute, it enters the rotary kiln for high-temperature calcination at 1250ºC to form active calcined white. It is then unloaded into the cooler, where it exchanges heat with the cold air blown in by the fan, cooling the active calcined white to below 100ºC, and the air is preheated to above 600ºC. The cooled active calcined white is discharged from the cooler and transported to the ball-making workshop by the plate conveyor. The entire process adopts a technologically advanced and reliable DCS central control system, which is operated and managed centrally in the main control room. 
The high-temperature flue gas generated by the rotary kiln combustion undergoes heat exchange with dolomite in the preheater, and its temperature drops below 250 - 280ºC. Then it enters the bag-type dust collector. After dust removal, the gas is discharged into the atmosphere through a high-temperature fan, and the dust concentration of the discharged gas is less than 30mg/m³.
 
Ball-making workshop 

The calcined dolomite is transported by the elevator to the 1# storage bin for standby; the silicon iron is crushed by the jaw crusher to less than 20mm, and then transported by the elevator to the 2# silicon iron block storage bin for standby; the fluorite powder is lifted by a single bucket and transported to the 3# storage bin. The three types of raw materials stored in the storage bins are continuously mixed and added to the ball mill by the microcomputer control for grinding. The particle size requirement is <100 mesh. The mixed powder then passes through the elevator, storage bin, and buried scraper conveyor, and enters the pelletizing machine to be made into pellets. The batching system selects an intelligent control system, and the entire process is fully realized by computer monitoring and fully automated operation. The ball mill is driven by a 10kV high-voltage motor, which reduces the power loss compared to the original 380V low-voltage power supply. 
The ball-making workshop is equipped with 3 dust removal systems. The C1# dust removal system is set up at the silicon iron crushing site, the C2# dust removal system at the batching and grinding area, and the C3# dust removal system at the ball pressing site. After comprehensive dust removal treatment, the working environment of the ball-making workshop has been significantly improved compared to the traditional workshop, and the working conditions of the workers have also been enhanced. 

Recovery and Refining Workshop 

The reduction furnace adopts the high-temperature air rapid reversing regenerative combustion technology. The regenerative reduction furnace uses gas as the fuel for continuous heating. The pellets are added into the reduction tanks in the reduction furnace by the feeding machine. The magnesium vapor generated in the reduction tanks condenses into crystalline magnesium (coarse magnesium) in the end condenser. The coarse magnesium is then taken out and sent to the refining and alloy production lines.

Advantages
1.Wide Product Grade Coverage
One line can produce light, heavy, refractory, feed, food, medical, electrical and nano MgO, flexible switch production without major equipment replacement.

2.Low Energy Consumption & Environmental Protection
Waste heat recycling system, closed negative pressure production, no dust leakage, exhaust gas meets international emission standards, support natural gas/electric clean heat source.

3.High Purity & Stable Quality
Independent temperature zoning control, impurity removal design, finished MgO purity up to 99.9%, uniform particle size, stable activity, consistent batch quality.

4.Full Automatic Intelligent Operation
PLC automatic control, automatic feeding, temperature adjustment, fault alarm, save labor cost, only 1-2 workers for whole line operation.

5.Customized Turnkey Solution
Custom capacity, kiln size, heat source, automation degree, provide free factory layout drawing, overseas installation, commissioning and training service.

6.Long Service Life & Low Maintenance
High-temperature alloy kiln lining, wear-resistant grinding roller, thickened dust removal shell, vulnerable parts long service cycle, simple daily maintenance.

Application Scope

• Refractory Industry: Dead burned MgO for steel furnace, cement kiln, glass kiln lining
• Rubber & Plastic Industry: Filler, anti-aging agent, flame retardant
• Feed & Agriculture: Animal feed magnesium supplement, soil conditioner
• Food & Pharmaceutical: Food additive, antacid raw material, nutritional supplement
• Environmental Protection: Flue gas desulfurizer, wastewater neutralizer
• Electrical Heating: Insulation powder for heating tube, electric heating elements
• Ceramic & Electronic: Electronic ceramic substrate, catalyst carrier

Item	Details
Product Name	Magnesium Oxide Production Line / MgO Manufacturing Plant
Raw Material	Magnesite Ore, Magnesium Hydroxide, Brine, Basic Magnesium Carbonate
Finished Product	Light MgO, Heavy MgO, High-purity MgO, Refractory Dead Burned MgO, Nano MgO
Production Capacity	500kg/h - 20t/h (Customized 1000T/3000T/10000T annual output)
Calcination Temperature	500-1600ºC Adjustable
Heat Source	Natural Gas, Diesel, Coal, Biomass, Electromagnetic Heating
Control System	PLC Central Control + Remote Monitoring, Automatic Temperature Control
Main Material	304/310S Stainless Steel, High-temperature Wear-resistant Alloy
Certificates	CE, ISO9001, ISO14001, SGS
HS Code (Equipment)	8417809000
Customization	Capacity, Kiln Size, Dust Removal, Automatic Packaging System
Warranty	12 months whole machine, lifelong technical support

 

Product Parameters

 

specification	Basic parameter			Reduction gear	Motor		Number of supports (PCS)	Machine weight (t)
	Speed (r/min)	Slope (%)	Yield (t/h)	Model number		Power (k W)
01.6×32m	0.24-2.4	4	2	ZS110-7	YVF2-180L-4	22	3	62
01.6/1.9×36m	0.24-2.4	4	2.5-3	ZQ110-7	YVF2-225S-4	30	3	68
01.9×39m	0.25-2.5	4	3-3.4	ZQ125-7	YVF2-225S-4	37	3	73
02.2×45m	0.27-2.7	3.5	4-5	The mainZS125-4	YVF2-225M-4	45	3	110
				Auxiliary:ZQ40-40	YE4-112M-4	4
02.5×50m	0.21-2.1	3.5	5-6	The main:ZS165-5	YVF2-250M-4	55	3	164
				Auxiliary:ZQ40-25	YE4-132M-4	7.5
02.5×55m	0.21-2.1	3.5	5-6	The mainZS165-5	YVF2-250M-4	55	3	170
				Auxiliary:ZQ40-25	YE4-132M-4	7.5
02.8×55m	0.22-2.2	3.5	6-7	The mainZS165-5	YVF2-280S-4	75	3	198
				Auxiliary:ZQ40-25	YE4-160M-4	11
03.0×60m	0.18-1.8	3.5	7-9	The main:ZS165-3	YVF2-355L2-6	132	3	226
				Auxiliary:ZQ40-25	YE4-160M-4	11
03.2×64m	0.2-2	3.5	8-10	The main:ZSY500-50	YVF2-355M1-6	160	3	327
				Auxiliary:ZSY180-25	YE4-160L-4	15
03.5×70m	0.2-2	3.5	12-14	The main:ZSY560-50	YVF2-355L1-6	220	3	375
				Auxiliary:ZSY200-25	YE4-180L-4	22
04.0×80m	0.2-2	3.5	16-20	The main:ZSY630-50	YVF2-3553-6	315	4	564.8
				Auxiliary:ZSY200-25	YE4-200L-4	30

Detailed Photos

Core: Magnesium Oxide Production Line, MgO Plant, Magnesia Calcination Line, Magnesite Processing Equipment

Long-tail: Light Magnesium Oxide Production Line, High Purity MgO Manufacturing Plant, Refractory Dead Burned Magnesia Kiln, Magnesium Hydroxide Calcining Equipment, Automatic MgO Powder Making Line, Turnkey Magnesia Production Project, Nano Magnesium Oxide Equipment, Feed Grade MgO Production Line
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