Hebei Leadership Friends Engineering and

Technology Co., Ltd

MG-Ingot Production Plant

Project: Oman-Mg-2025-01
Document: LF-B-DSN-75-1

Basic Design
1/2/2025

Client : Sanvira Version2

 Summary
Each section seems to focus on specific aspects essential for the planning, construction, and operational
functioning of an industrial enterprise, providing detailed insights into its infrastructure, processes, and systems.
• Chapter 1: Construction Conditions, Which mainly should be provided by client
Production Technology This section likely delves into the technology and methodologies used in the production
process within the enterprise.
Main Technical and Economic Indicators : This part focuses on key technical and economic metrics used to
measure the efficiency, productivity, and profitability
• Chapter2: Construction Conditions
Geographical Location and Transportation : Discusses where the enterprise is situated and the transportation
facilities available in that area.
Raw Material and Fuel Resources: Covers the availability and access to necessary raw materials and fuels for the
production process.
Power Supply and Water Supply : Details the sources and infrastructure for power and water supply to the
enterprise.
Meteorological Conditions and Earthquakes : Deals with environmental factors like weather conditions and
seismic risks in the area.
• Chapter 3: General Layout
Construction Site Location : Explains the chosen location for building the enterprise and its factors.
Layout Principles : Discusses the fundamental principles guiding the design of the layout.
Overall Planning : Covers the comprehensive planning strategy for the enterprise.
Functional Zoning: Details how different areas or zones within the enterprise will be allocated for specific
functions.
Roads Inside and Outside the Factory: Discusses the road network within the enterprise and its connections to
external roads.
• Chapter 4: Production Process
Material Balance : Discusses the balance between input and output materials in the production process.
Production Process : Explains the process through which the materials are transformed into the final product.
• Chapter 5: Building Structures
covers details about the physical structures, buildings, and their specifications.
• Chapter 6: Electrical and Automation
Design Scope : Outlines the scope of the electrical and automation systems.
Power Supply and Distribution System : Discusses the infrastructure for supplying and distributing power within
the enterprise.
Automation Control System : Details the system used to automate processes within the enterprise.
Main Equipment Automation Control System Scheme : Likely provides specifics on how the automation of main
equipment is implemented.
Electrical Energy-Saving Measures : Discusses measures taken to conserve electrical energy.
• Chapter 7: Utility Systems
Design Scope : Outlines the scope of various utility systems.
Circulating Water System : Covers the system used for circulating water within the enterprise.
Compressed Air and Nitrogen System : Likely discusses systems related to compressed air and nitrogen.
Laboratory : May cover the design and specifications of the laboratory within the enterprise.

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 Index

Chapter 1 - General 4
1.1 Project Name and Undertaking Unit
1.2 Design Basis and Scope
1.3 Main design principles
1.4 Construction scale and product plan
1.5 Production Technology 5
1.6 Main technical and economic indicators
6
Chapter 2 Construction Conditions 8
2.1 Geographical location and transportation conditions of the enterprise
2.2 Raw material and fuel resources
2.3 Power supply and water supply
2.4 Meteorological conditions and earthquakes

Chapter 3 General Layout 9

3.1 Construction site location
3.2 Layout principles
3.3 Overall planning
3.4 Functional zoning 11
3.5 Roads inside and outside the factory

Chapter 4 Production Process 14

4.1 Material balance
4.2 Production process

Chapter 5- Building Structures 53

Chapter 6 - Electrical and Automation 55

6.1 Design scope
6.2 Power supply and distribution system
6.3 Automation control system 59
6.4 Main Equipment Automation Control System Scheme 63
6.5 Electrical energy-saving measures 70

Chapter 7 - Utility Systems 72

7.1 Design scope
7.2 Circulating water system
7.3 Compressed air and nitrogen system 74
7.4 Laboratory

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Chapter 1 - General

1.1 Project Name and Undertaking Unit

1.1.1 Project Name

Construction project of an annual production line for 14,200 tons of metallic magnesium by
Sanvira company
1.1.2 Introduction to the Project Construction Unit

1.2 Design Basis and Scope

1.2.1 Design Basis

1. The topographic survey map of the factory area provided by the construction unit, the basic
conditions for building the factory, and other document agreements.
2. The Preliminary Design Contract and Preliminary Design Technical Agreement signed
between the Client and the design unit
1.2.2 Design scope
The basic principle of this construction project is to utilize the abundant local resources such as
dolomite and natural gas to produce an annual production line of 14,200 tons of metallic
magnesium, and reserve a second phase construction site. The construction scope includes the
process, structure, architecture, electrical, instrumentation, process control, water supply and
drainage, and overall layout design from the entry of raw materials into the factory to the
delivery of finished products. Mainly including calcination production system, grinding and
briquette system, reduction system, refining system, and finished product storage and delivery.

1.3 Main design principles

1, The overall design principles of this project are "mature technology, reliable production,
saving investment, improving efficiency, and emphasizing environmental protection".
2, When choosing a production process plan, based on careful investigation and research,
make a good comparison of the plan, and try to use mature and reliable new processes and
technologies as much as possible, achieving both advanced technology, economic rationality,
and practical reliability.
3, Electrical and automation control should consider advanced technology, mature and reliable
equipment and instruments, and their simplicity and applicability.

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4, Meet local environmental protection requirements and actively implement the principle of
energy conservation and consumption reduction.

1.4 Construction scale and product plan

1.4.1 Construction scale

The construction scale of the production area of this project is an annual production line of
12,000 tons of metallic magnesium, and a second phase construction site is reserved.
1.4.2 Product Plan
The chemical composition of the metallic magnesium produced in this project refers to the
standard of "Primary Magnesium Ingots" (GB/T3499), and its specific composition is detailed
in the table below
Mark Chemical composition (mass fraction)%
Impurity elements, ≯
Mg≮ Other
Fe Si Ni Cu Al Mn Ti Pb Sn Zn
impurities

Mg9999 99.99 0.002 0.002 0.0003 0.0003 0.002 0.002 0.0005 0.001 0.002 0.003 ---

Mg9998 99.98 0.002 0.003 0.0005 0.0005 0.004 0.002 0.01 0.001 0.004 0.004 ---

Mg9995A 99.95 0.003 0.006 0.001 0.002 0.008 0.006 --- 0.005 0.005 0.005 0.005

Mg9995B 99.95 0.005 0.015 0.001 0.002 0.015 0.015 --- 0.005 0.005 0.01 0.01

Mg9990 99.90 0.04 0.03 0.001 0.004 0.02 0.03 --- --- --- --- 0.01

Cb, Hg, As, Cr6+ Elements, the client may not perform routine analysis, but their content should be
monitored. Requirements W(Cb+Hg+As+Cr6*)≤0.03%

1.5 Production Technology

Based on the raw material analysis report provided by the client, combined with the
production experience of domestic metal magnesium production enterprises in China, this
project adopts the silicon thermal production process. Taking into account the characteristics
of the silicon thermal production process and the actual situation of the factory, the
production line of this project is divided into five parts:
1.5.1 Dolime calcination production system
This project adopts a preheating calcination production system for dolime calcination,
consisting of a six push head preheater, Φ 3× 50m rotary kiln, 3.8 × 3.8 Vertical cooler
composition, with a production capacity of 260-280t dolime per day and a heat consumption
of 1400kcal/kg dolime. The fuel uses natural gas.
1.5.2 Grinding and pressing ball system

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The batching of the grinding and pressing ball system is measured using a static weighing scale,
and one grinding machine is used for grinding Φ 2.4 × An 8m ball mill with an hourly output of
18-20 t/h. 3x10tph briquette machines (two in use and one backup) are used for briquette.
1.5.3 Reduction System
The reduction system of this project adopts a vertical tank reduction process using natural gas
as fuel. The reduction system is equipped with 2x144 vertical tank thermal storage reduction
furnaces and a mechanical vacuum system. Reduction furnace usage Φ 630 ×4000mm
reduction tank with a designed magnesium to material ratio of approximately 6.5, with
reduction time of 16-20 hours, and a single tank output of 120kg.

1.5.4 Refining workshop

The refining workshop is a production workshop that integrates crude magnesium refining and
pouring. The equipment consists of a natural gas refining furnace, insulation furnace, pouring
furnace, and other supporting auxiliary equipment.

1.5.5 retort(tank) making and maintenance workshop

The reduction tank and refining workshop crucible in this project are vulnerable parts with
high annual consumption. A can making and maintenance workshop is specially set up for the
production and maintenance of the reduction tank, as well as the maintenance of other
equipment. The can making and maintenance workshop is mainly equipped with 2x3.5-ton
electric furnaces, a set of centrifugal casting machines and other supporting facilities, with a
production capacity of one reduction tank per hour, meeting the requirements of this project.

1.5.6 Auxiliary production facilities

The auxiliary production system of this project includes finished product warehouse, central
control room, substation, distribution room, circulating water system and other auxiliary
production facilities to meet the requirements of the construction project.

The living facilities include office buildings, dormitories, canteens, and necessary living aids for
bathrooms. The civil design and construction of this project are entirely the responsibility of
the client.

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1.6 Main technical and economic indicators

No Item Unit Data Remark

One Engineering construction scale
Magnesium metal ktpa 1.42
Total installed capacity of the
Two KW 12000
project
11/6.6kV high-voltage capacity kW 1810
400V low-voltage capacity kW 10190
Three Electricity and water indicators
Annual power consumption 19.14million Whole plant
1 Daily water consumption KW.h/a 120
2 m3/d As 0.4%
evaporation
Four Labor quota
Production workers man 280
administrative staff man 20
Total man 260
Five Energy consumption indicators
1 NG consumption NG m³/t 2400
2 Comprehensive electricity KWH/t 1340 8500kcal/Nm3
consumption

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Chapter 2 Construction Conditions

2.1 Geographical location and transportation conditions of the enterprise

2.1.1 Geographical location of the project

2.1.2 Natural Physical Environment
2.1.2.1 Topography
2.1.2.2 Geological structure
2.1.3 Hydrology
2.1.3.1 Rivers
2.1.3.2 Groundwater
2.1.4 Transportation
(Above omitted, waiting for client improvement)

2.2 Raw material and fuel resources

2.2.1 Dolomite
As the dolomite used in the Pidgeon process for magnesium smelting, it should not only
meet the process requirements in terms of chemical composition, but more importantly, in
terms of mineral structure, it should meet the requirements of the smelting process, because
the chemical composition and mineral structure of dolomite have a significant impact on the
various processing of this process.
The chemical composition of dolomite theoretically contains 21.8% MgO, 30.4% CaO, CO2
47.68%, CaO/MgO=1.394 (mass ratio), CaO/MgO=1.0 (molar ratio). The chemical composition
of dolomite used for magnesium smelting by the silicothermic method (Pidgeon method) in
China should meet the following requirements:

Mg0 CgO Al2O3 Fe2O3 SiO2 K2O+Na2O

19-21 30-33 <0.5 < 0.5 < 0.5 < 0.01

The general requirement is that the wear resistance index R1 of dolomite is less than 10%, and
the ash ratio R2 is less than 1.5% . The particle size of raw materials is required to be 20-40mm,
and impurities such as mud and sand should be avoided as much as possible.

The mineral structure requires small grains, polycrystalline, lattice like, and network like
structures, without any specific shape. Its color is light gray, and the ore has high mechanical
strength, hard texture, and is not easy to break. When broken, the powder ratio is small. When

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burned at high temperatures, its thermal intensity is high and its thermal cracking is small.
2.2.2 Ferrosilicon
Oman has sufficient local supply of ferrosilicon, and this project is also preparing to build a
ferrosilicon plant, which can meet the needs of this project. The main components of
ferrosilicon should meet the requirements of containing 25% Fe and 75% Si, with a particle size
less than 15mm.

2.2.3 Fluorite
Fluorite, as a co solvent in the reduction process, is added during the briquetting process,
accounting for about 1-3% of the total amount and can be purchased nearby.

2.2.4 Other materials

Other materials for producing magnesium alloys, including solvents and various alloy materials,
can be purchased in the market. Build a self owned reduction tank manufacturing workshop
for the required reduction tanks in production.

2.2.5 Fuel - Natural Gas

Oman has sufficient natural gas supply and low prices, fully meeting the needs of this project.
The calorific value of natural gas is generally greater than 8000Kcal/m ³, The client is
considering building a natural gas station in the factory area, which will be delivered gas to
each workshop through pipelines.

2.3 Power supply and water supply

This project requires a large amount of electricity, and client is responsible for connecting the
dual circuit power supply from the higher-level step-down station. A main step-down station
and workshop substation are set up in the factory area, with a production voltage level of
11/6.6kV and 0.4kV.

The production and daily water use of this project shall be the responsibility of The Client to
divert water or drill wells at the construction site as the water source for this project.
The factory is equipped with facilities such as reservoirs, circulating water tanks, and water
treatment systems, and the water supply capacity of the water source should meet the needs
of the factory.

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 ▲ Water quality requirements for metal magnesium production lines
Standard code Water quality（mg/L） Remark
GBJ29—90 item Based on CaO Based on CaCO3 Drainage
temperature ℃
Calcium ≤140 ≤250 45
carbonate 168 330 40
hardness 196 350 35
280 500 30

2.4 Meteorological conditions and earthquakes

2.4.1 Meteorological conditions

2.4.2 Earthquake
According to Oman Seismic Fortification Intensity Zoning Map, the seismic intensity of the
area is Ⅲ degrees, and the construction of the site should be fortified according to degree
zones.
2.4.3 Construction site geology
Please refer to the geological survey report for details

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Chapter 3 General Layout

3.1 Construction site location

Sohar, Oman

3.2 Layout principles

1. Implement the current national standards and requirements for fire prevention, explosion
prevention, safety and health, and environmental protection.
2. Make full use of the site, arrange the overall plan reasonably and compactly, and ensure
smooth traffic organization within the factory.
3. The process flow is smooth and simple, with a reasonable flow direction.
4. Based on natural conditions such as wind direction and terrain, arrange according to local
conditions to ensure that most buildings have a good orientation.
5. Reasonably arrange roads to facilitate transportation within the factory, clearly define
functional areas, and facilitate communication between inside and outside the factory.

3.3 Overall planning

Based on the surrounding environment of the factory and the area occupied by the factory,
plan the total production scale of metallic magnesium for the project, with an annual output
of 14280 tons, and reserve a construction site for the second phase.

The main construction content includes: calcination dolime production system; Grinding and
briquetting system; reduction system; The refining workshop, tank making and maintenance
workshop, as well as water, electricity, office, and living service facilities that are compatible
with the project.

3.4 Functional zoning

The overall layout is based on the transportation route connection conditions of the factory
site, the terrain, topography, engineering geology, and meteorological conditions of the
factory area. It considers the reasonable and smooth process flow, compact connection
between various processes, as well as the ability of living and welfare facilities and mechanical

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and electrical maintenance, reducing engineering investment, and considering the
convenience of power supply Gas supply and water supply line design in the factory area.
Based on the above principles and combined with the actual situation, propose the functional
zoning of this design, and strive for a neat appearance and smooth process in the layout of the
production line; The main roads in the factory area run through the factory area, providing
convenient transportation.

According to local meteorological data (annual dominant winds, etc.) and the owner's
requirements, the transportation conditions outside the factory are separated by roads in
each functional area. The overall layout is as follows:

1. office and living service facilities are arranged in the southern part of the entire factory
area, and the designed land area can meet the development requirements of the two
phases of the factory.

2. On the west side of the construction site, a dolomite storage yard, a calcination
production line, a grinding and briquetting workshop, a reduction workshop,

3. a reduction slag yard will be set up from north to south.

4. The westernmost side is reserved for the use of land for the second phase of the
project.

5. The central control, distribution room, and laboratory are located in the middle of the
two phases of the project.

6. In the middle of the construction site, from north to south, machine repair, reduction
tank workshop, main pressure reduction station, air compressor station (equipped with
air compressor and nitrogen generator), refining workshop, and magnesium ingot
warehouse are set up. And reserve the construction site for the pilot plant.
7. The eastern part of the construction site is a silicon iron production line as required by
the owner, which is not within the scope of this project.

Due to the relatively flat construction site, the vertical layout design plan of the construction
site is as follows:
The workshop of this project adopts a unified elevation of ± 0.00, and the ground rainwater
drainage is done through open ditches along the road from north to south.

3.5 Roads inside and outside the factory

According to the process flow and logistics, this project sets up a raw material entrance gate
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on the northwest side of the factory area, and an electronic car scale is set up at the entrance
of the gate for the transportation of raw materials into the factory for measurement; A
finished product and waste residue factory gate is set up on the southwest side of the factory
area for transportation of finished products and waste residue.

In the middle of the south side of the factory, a gate is set up to handle the flow of people and
external communication channels.

After the project is put into operation, the entry of various raw materials and spare parts, as
well as the delivery of finished products and waste residue, will be mainly carried out by truck
transportation, which will be jointly undertaken by the company's transportation team and
external transportation vehicles from society.

The design of roads in the factory area is based on the principles of smooth material
transportation, convenient workshop connections, and compliance with fire safety
regulations.

According to the transportation characteristics of raw materials and finished products, the
circular roads or main roads in the factory lead to major production workshops and raw
materials, as well as the gathering points of finished products. The roads in the factory area
are all paved with concrete, and the main roads are urban lanes.

The internal transportation of production mainly involves the secondary transportation of raw
materials and fuels, stacking and storage, as well as the transportation of other materials for
production services. The Client will provide supporting loaders and forklifts as needed.

The greening of the factory area is set up by The Client in accordance with local regulations,
and this design is not discussed in detail.

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 Chapter 4 Production Process

4.1 Material balance

Material balance (t)

Natural
dry moisture
No. material moisture
Per Per hour
（%） Per day Per year Per day Per year
hour
1 Magnesium metal 1.80 43.29 14284.80
2 Calcined dolime 9.63 231.08 78566.40
3 ferrosilicon 1.89 45.45 14999.04
4 fluorspar 0.27 6.49 2142.72
5 dolomite 1 18.38 441.15 149990.40 18.57 445.60 151505.30
6 Briquette ball 11.73 281.49 95708.16
Reduction tank 0.05 1.17 385.69
7
material
8 Reducing slag 9.38 225.09 74280.96
Natural gas (10,000 0.43 10.26 3425.62
m³)
9 Calcination system 0.17 4.08 1386.47
Reduction system 0.24 5.70 1882.02
Refining system 0.02 0.48 157.13

Note:
1. Using magnesium metal as the calculation benchmark;
2. The production line operates for 330 days annually (with an annual operating rate of 90%);
3. The calorific value of natural gas is calculated at 8500Kcal/m ³ calculate
4. The total amount of dolomite is calculated based on 5% of the particle size being
unqualified

4.2 Production process description

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 Dolomite

Gas station Vertical preheater

75# ferrosilicon Rotary kiln workshop Bag dedustor Desulfurization Emission

tower

elevator cooler

Kneading machine elevator elevator

Ferrosilicon bin Burnt D bin Fluorite bin

E batching scale E batching scale E batching scale

Ball mill Bag dedustor

Emission

Briquette Briquette Briquette Briquette

Recycling water pool

Reduction workshop
Vacuum pump
Slag to cement factory

desulpher tower Emission

Refinery workshop

Finished Mg stockyard

The project process design is based on

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 • the principles of reliable performance,
• advanced technology,
• economic practicality,
• energy conservation
• and consumption reduction.

While ensuring reliable equipment operation, product quality, and environmental protection
standards, priority is given to the selection of imported technology and local manufactured
high-efficiency energy-saving equipment.

The technical scheme is optimized to minimize construction investment and maximize

economic benefits for the project. At the same time, we attach great importance to
environmental protection and energy conservation, take effective measures to control and
control dust pollution, reduce material production losses, and ensure that the dust emission
concentration at each emission point meets the national standard requirements.

4.2.1 Dolime calcination production system

The calcination production system uses dolomite as raw material and produces magnesium
oxide through calcination. The calcination of dolomite is actually the heating and
decomposition of dolomite. Dolomite is a composite of CaCO3 and MgCO3. The basic reaction
of dolomite calcination, which is the heating decomposition reaction of carbonate, is an
extremely important process in the entire production process of metallic magnesium.

This project adopts a preheating calcination production system for dolime calcination,
consisting of a six push head preheater, Φ 3× 50m rotary kiln, 3.8 × 3.8 Vertical cooler
composition, with a production capacity of 260-280t calcined dolime per day and a heat
consumption of 1400kcal/kg calcined dolime. The fuel uses natural gas.

4.2.1.1 Raw material storage, transportation, and transportation

After sieving, the dolomite with a particle size of 20-40mm is transported from the mine to the
factory area and stacked in the material yard. The dolomite passes through the hopper and is
fed into the belt conveyor by a vibrating feeder under the hopper. The belt conveyor is then
fed into the screening frame. A vibrating screen is installed at the top of the frame to screen
out particles smaller than 20mm generated during transportation and stacking. The dolomite
with a particle size of 20-40mm is sent to the kiln tail preheater through a belt conveyor.

Dolomite feeding, the dust generated during the screening process is treated by two pulse bag
dust collectors. The dust collected by the bag dust collectors and particles smaller than 15mm
after screening enter the screening material bin.
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4.2.1.2 Calcination of dolomite

The materials are introduced into the preheater body through the feeding chute from the top
silo of the preheater. At the same time, the high-temperature flue gas introduced by the
rotary kiln exchanges heat with the materials, preheating them to around 900 ℃ to partially
decompose the dolomite. Then, 6 hydraulic push rods are sequentially pushed the material
into the tail of the rotary kiln, and after 1250℃~1300℃ high-temperature calcination in the
rotary kiln; they are unloaded into the vertical cooler.

Cold air is blown in by the fan, and cool the material to an ambient temperature
below+100-150 ℃. The air blown in by the vertical cooler enters the rotary kiln as secondary
air to participate in combustion, because the secondary air passing through the vertical cooler
is preheated to around 600 ℃, which can effectively increase the firing temperature inside the
kiln and reduce fuel consumption.

The cooled lime is discharged by a closed electric vibrator at the bottom of the vertical cooler,
and then transported to the finished lime conveying and storage system through a chain
conveyor. A pulse bag filter is installed on one side of the kiln hood and cooler to remove dust
from the cooler and discharge point.

The main function of the vertical preheater is to deliver the dolomite material sent from the
upper part to the preheater body, and at the same time, use the waste gas (850-1000 ℃)
discharged after calcination in the rotary kiln to evenly preheat the material in the preheater
to -900 ℃, and then push it into the rotary kiln by hydraulic push rod for calcination.

This calcination process not only greatly shortens the calcination time of dolomite in the kiln,
but also achieves high activity of calcination. The structure of a vertical preheater, in addition
to electrical control, mainly consists of four parts:
1. The first is the upper feeding system, which mainly includes the upper material bin,
feeding pipe, feeding method and structure to ensure complete sealing when feeding
into the preheater body. This way, cold air from the outside cannot enter the
preheater, and the feeding can be achieved continuously or intermittently through a
rod valve.
2. The second is the main body of the preheater, which is the most important part to
ensure that the materials are preheated to around 900 ℃. It is composed of the
preheater cylinder, material distribution arch, suspension device, and refractory brick
lining. The structure of this section is mostly made of metal components, and some
materials are selected as heat-resistant steel according to needs. The heat-resistant
steel can work at high temperatures of 1000-1100 ℃. In addition, the design of the
refractory brick lining structure is novel, which can ensure that the material is
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 uniformly preheated in the preheater and reaches the preheating temperature.
3. The third is the hydraulic push rod device, which mainly includes push rods, frames,
and connecting rods. The push rods are made of heat-resistant steel castings and can
withstand high temperatures. With the help of electronic control and hydraulic
systems, the 6 hydraulic push rods can achieve automatic control program sequential
feeding.
4. The fourth is the framework, which mainly includes columns, ring beams, etc., and its
main function is to support the upper structure of the preheater.

Dolomite is uniformly preheated to around 900 ℃ in the preheater by the kiln tail gas at
850-1000 ℃. The exhaust gas is collected through the six exhaust holes on the upper part of
the preheater and enters the kiln tail gas treatment system.

The partially decomposed dolomite is pushed into the feeding chamber by the hydraulic push
rod on the preheater. The feeding chamber mainly includes a chute, the main body of the
feeding chamber, the feeding vessel, etc. Its main function is to guide the preheated material
into the rotary kiln for calcination.

After calcination, the calcined dolime material enters the single barrel cooling machine for
cooling through the kiln discharge device, cooling the calcination temperature from about
1150 ℃ to below the ambient temperature of 100-150 ℃.

4.2.1.3 Waste gas treatment

The high-temperature flue gas generated by the combustion of the rotary kiln undergoes heat
exchange with dolomite in the preheater, and the temperature drops below 260 ℃. After
passing through a cyclone dust collector, the flue gas temperature further decreases, and then
enters a bag filter.

After dust removal, it is discharged into the atmosphere through a high-temperature fan, and
the dust concentration discharged into the atmosphere is less than 50mg/Nm3, which meets
local emission standards.

The kiln tail dust collector adopts the advanced long bag low-pressure pulse dust collector in
China, which has the advantages of large processing capacity, high dust removal efficiency,
and wide range of use. The dust collector type of this project has a processing air volume of
130.000 m3/h, a filtering area of 2.880 square meters. There is a steel chimney behind each
dust collector.

Due to the temperature of dolomite reaching~900 ℃ in the preheater, magnesium oxide and
calcium oxide have been generated on the surface, which can fully react with sulfur dioxide in
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the flue gas, and the desulfurization efficiency can reach over 90%.

4.2.2 Grinding and briquetting system

The reduction reaction of metallic magnesium belongs to solid-phase reaction, which takes
place on the surface between the reducing agent and the calcined particles. The quality of the
contact between the materials determines the reduction reaction rate of magnesium oxide.

Therefore, after the calcination, reducing agent ferrosilicon, and mineralizing agent fluorite
are mixed and ground finely, they indirectly contact each other well through briquetting,
which is conducive to the progress of the reduction reaction process.

Due to the absorption of moisture in the air during storage, the reduction reaction rate of
magnesium oxide is reduced. Therefore, the selection of the grinding system must be designed
according to its characteristics. In this project, one grinding system is used ф 2.4 × 8m open
circuit ball mill, equipped with advanced static scale batching, metering, and dust collection
system using pulse dust collector.

The production capacity of this system is 15-18t/h, with advantages such as simple operation,
accurate batching and measurement, and lower exhaust gas emissions than national
standards.

The specific process flow is as follows:

4.2.2.1 Batching system

After cooling from the cooling machine, the calcined dolime is sent to two bins through an
elevator, Φ6 ×18m calcined dolime finished product bins. The bottom of the calcined dolime
finished product bins adopts a suspended metal scale weight loss scale; After being measured,
it is sent to the ball mill.

After the ferrosilicon with a diameter of less than 15mm enters the factory, it is fed into a
ground pit, an electric vibrator, and a hoist Φ 6×18m ferrosilicon bin is used for storage, and
the bottom of the ferrosilicon bin is measured using a suspended belt weight loss scale.

At present, all magnesium metal production enterprises use fluorite powder as the
mineralizing agent for the reduction system. This project adopts Φ4. 5×6m steel bin serves as
the fluorite batching warehouse, and the bottom of the bin is measured using a suspended
belt weight loss scale.

Calcined dolime, ferrosilicon, and fluorite are all measured using weight loss scales, and the
automatic batching system measures accurately, which can be quickly adjusted according to
the material composition to ensure the magnesium yield of the reduction system. The
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measured material is conveyed by a belt conveyor to a ball mill for grinding.

4.2.2.2 Grinding and briquetting

The measured material enters the ball mill for grinding, and the mixed material with qualified
fineness is discharged through the grinding tail and sent to the mixing bin for use by the
briquetting system.

Bag dust collectors are installed at each dust collection point of the grinding system to
improve the operating environment in the workshop and reduce the losses caused by material
dust. The collected dust enters the mixing silo, and there is no waste discharge in this system.

3xLYQ10 high-pressure roller briquette machines (two in use and one backup) are selected for
this project's briquette equipment, with a maximum system output of 20 t/h. The process flow
is as follows:
• the powder produced by the mill is fed into the mixing bin through the conveying
equipment,
• the materials in the bin are sent to the pre pressing bin of the briquette machine
through the chain conveyor.
• After being compressed by the briquette machine on the rollers, they are compressed
into 2.54 × 3.81×7.62cm walnut shaped pellets are loaded into the feeding ball cart,
• they are sent to the reduction workshop through the track.

The exhaust gas generated by the briquetting system is treated by the dust collector and
discharged. The fragments generated during the briquetting process are transported by the
conveying equipment to the mixing bin for re pressing.

The grinding system is equipped with a PPS64-5 gas box pulse bag dust collector, with a
processing air volume of 17,800m3/h, a filtering area of 256 ㎡, and a filtering wind speed of
1.2m/min.

The briquetting is equipped with one PPS64-5 gas box pulse bag dust collector, with a
processing air volume of 22,300m3/h, a filtering area of 320 ㎡, and a filtering wind speed of
1.2m/min.

4.2.3 Reduction System

The reduction system consists of a vacuum section, a reduction section, and a heating section,
forming an organic whole that should meet the following requirements:

(1) Due to the boiling point temperature of magnesium being 1107 ℃, the reduction process
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temperature is generally controlled between 1180-1200 ℃. The heating part should be able to
provide and reach the required temperature.

(2) Due to the fact that the reduction reaction should be carried out under vacuum conditions
of 1.33~10Pa, the reduction tank must be able to withstand various pressures up to an
atmospheric pressure at a temperature of 1200 ℃ or higher.

(3) The vacuum unit can discharge the gas in the system within the time required for loading
and closing the reduction tank, achieving a residual pressure of 13.33Pa.

(4) Equipped with a continuous condensing system to reach a suitable temperature,

magnesium can crystallize densely and remove easily ignitable alkali metals accordingly.

4.2.3.1 Reduction furnace

This project adopts a thermal storage reduction furnace. The thermal storage reduction
furnace overcomes the shortcomings of traditional metal magnesium reduction furnaces, such
as low combustion efficiency, serious heat waste, uneven temperature inside the furnace,
difficult temperature control, and serious pollution.

The characteristic of a heat storage reduction furnace is that the heat storage chamber is filled
with a heat storage body. Set up a conversion system outside the furnace. The furnace body is
constructed in layers using various refractory materials. The reversing system, fan, and heat
storage chamber are connected by pipelines. The reversing system controls the flow of air and
gas. Valves are installed on the pipeline to control its flow rate. A temperature measurement
hole is installed at the top of the reduction furnace to maintain the surface temperature of the
reduction tank at 1180-1200 ℃.

Working principle of regenerative magnesium reduction furnace: The regenerative chamber

unit composed of multiple regenerative chambers is in a cross arrangement state at one end
of the furnace side, and each type of regenerative chamber is equipped with multiple rows of
distributed burner nozzles, which are symmetrically arranged at the other end. Air and natural
gas pass through a reversing system, and the pipeline enters the heat storage chamber group
for preheating to around 1000 ℃. Then, they enter the furnace through rows of distributed
burners on the heat storage chamber.

The preheated air and gas undergo intense combustion, generating a large amount of heat.
The tank body of the reduction tank is heated, and the smoke generated by combustion enters
the right heat storage chamber group through the right burner nozzle. At this point, the heat
storage chamber on the right is in a heat absorbing state. When the flue gas passes through, a
large amount of heat carried by the flue gas is absorbed by the heat storage body in the right
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heat storage chamber, and then discharged from the chimney to the outside of the furnace
through the pipeline and reversing system.

After a turning cycle, the original heat storage chamber group releases heat, while the original
heat storage chamber group absorbs heat. At this point, the reversing system operates,
changing the path of air and gas entering the furnace. The direction of gas and air entering is
opposite to the original direction of entry. Repeat the combustion process described above
and repeat it over and over again.

After this combustion process, the flue gas temperature significantly decreases, dropping from
around 1200 ℃ in traditional combustion methods to below 150 ℃, effectively utilizing
energy and reducing losses. Effectively controlling the flow of gas and air can effectively
control the temperature inside the furnace, avoid large temperature fluctuations in the
furnace, and improve the service life of the reduction tank. Ensure that the temperature inside
the furnace fluctuates only slightly around the optimal reduction temperature, thereby
improving the yield and quality of magnesium metal.

The combustion methods of high-efficiency, energy-saving, and environmentally friendly

thermal storage reduction furnaces are direct combustion curtain wall type and diffusion
combustion type. Due to the flue gas temperature discharged from the furnace being below
150 ℃, the thermal utilization rate of the reduction furnace can be increased from the original
8-10% to over 50%, which has good energy-saving effects and good economic and
environmental value. Strengthening the service life of the reduction tank has more practical
significance in improving the production and quality of magnesium metal.

This project adopts two 144 tanks metal magnesium reduction furnaces, with magnesium
discharged from the top and slag discharged from the bottom of the reduction tanks. The
reduction time is 16-20 hours.

Thermal detection and computer control system for reduction furnace:

1) System characteristics
This system adopts a programmable controller to form a practical and reliable automatic
control system.

2) Mainly detecting display and control items

2.1) Automatic control project
Automatic combustion reversing control
Automatic control of furnace temperature
2.2) Temperature detection items
Two point temperature detection for the entire furnace, displaying
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 Temperature detection in front of the directional valve, displaying
One point temperature detection in front of the smoking machine, displaying
2.3) Pressure measurement items
Natural gas main pipeline pressure detection, displaying
One point combustion air main pressure detection, displaying
Compressed air main pressure detection, display
2.4) Flow measurement items
Natural gas flow detection, display
Air flow detection, display
Smoke flow detection, display
2.5) Security alarm project
Furnace temperature over temperature alarm
Alarm for over temperature of exhaust gas in front of directional valve and smoke
exhaust fan
Low pressure alarm in the main pipe of the combustion fan
Abnormal operation alarm of directional valve
Compressed air main pressure too low alarm
3) Main control processes
• Furnace temperature
Due to the adjustable natural gas pressure and clean energy used in the
furnace, a flow measurement device is installed on the pipeline. This plan
adopts a manual adjustment method to control the furnace temperature.
The pressure, temperature, and flow signals of each measuring point are
displayed together on the control cabinet for reference by operators when
adjusting furnace temperature and combustion ratio.
• Furnace temperature control
To stabilize combustion and prevent cold air intake, the system sets the
furnace pressure to be in a slightly positive state of 0-80pa. This plan adopts
manual adjustment of furnace pressure and is equipped with a manual
adjustment valve(According to process requirements, manual adjustment is
required here)
• Directional valve control
The reversing system has flexible manual, semi-automatic, and fully
automatic control functions.
• Temperature control of exhaust gas from thermal storage room
The main basis for setting the exhaust temperature of the heat storage room
in the control system is the dew point temperature of the flue gas and the
allowable operating temperature of the equipment. The smoke exhaust

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 temperature is generally set at 150-200 ℃, with timed directional control as
the main method and constant temperature directional control as the
auxiliary method to control the smoke exhaust temperature.

4.2.3.2 Reduction tank

• The high-temperature part (reaction zone) of the reduction tank in the furnace is made
of heat-resistant nickel chromium alloy.
• The protruding part (magnesium condensation zone) of the reduction tank is made of
carbon steel pipe.
• A cylindrical condenser is installed in the carbon steel pipe, and a cooling water jacket
is welded on one end of the steel pipe near the tank cover to control the temperature
of the condensation zone.
• An alkali metal trap is installed at the outer end of the cylindrical condensation zone
for condensing alkali metals.
• There is an insulation board placed between the furnace material and the condenser,
which is composed of two layers of thin iron plates with holes. The holes on the board
do not correspond to each other and are used to block the radiation heat of the
furnace material to prevent the temperature of the condenser from rising.
• The reduction tank is sealed with a cover with a vacuum rubber gasket, and a 90
degree vacuum pipe joint connected to the vacuum system is welded on the tank wall
near the cover.

The reduction tank used in this project adopts Ф 630 × 4000mm vertical reduction tank with
central cylinder diameter Ф 273mm, using the process of upper magnesium discharge and
lower slag discharge, the crude magnesium output of a single tank is 120kg. The annual output
of two reduction furnaces is calculated as:
(330× 24/19.1613) × (120x144 × 2/1000)=413.3333 × 34.56= 14284.8 tons/year

4.2.3.3 Vacuum unit

The task of a vacuum unit should first ensure that a large amount of gas is extracted under
normal pressure at the beginning of the reduction cycle, and secondly, maintain a
considerable extraction speed throughout the entire reduction process to achieve a vacuum
degree below -5Pa. This project adopts the J2ZH2800 series mechanical vacuum unit, which is
composed of
a through type vacuum valve,
• vacuum relay,
• Roots vacuum pump,
• metal corrugated pipe,
• clamp type butterfly valve,
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 • electromagnetic relief valve,
• and slide valve vacuum pump.

Each reduction furnace is equipped with 28 sets of mechanical vacuum units as backup to
ensure the normal use of the reduction system.

4.2.4 Refining system

This production line is used as equipment set for one-step production of magnesium ingots
and magnesium alloy ingots by adding auxiliary materials from raw magnesium. The
equipment consists of:
• thermal storage melting furnace,
• insulation pouring furnace,
• intelligent control system,
• ingot casting machine,
• and other auxiliary equipment.

The system adopts intelligent control, with a high degree of automation and saves labor. The
control system adopts computer intelligent control, and after the entire set of equipment is
put into operation, it can achieve an annual production capacity of 14,000 tons of magnesium
ingots.

4.2.4.1 Equipment composition

1. Adopting a layout of 1sets, 4 in2, with 4 magnesium thermal storage melting furnaces
and a capacity of 3.5 tons;
2. one set of resistance type magnesium alloy insulation furnaces with a capacity of 3.0t;
3. One flux furnace and one recovery furnace each, with a capacity of 1.5 ton of flux, used
for cleaning preheating transfer pumps and casting pumps;
4, One set of 96 molds magnesium alloy ingot casting machines, automatic quantitative
casting of magnesium ingots, capable of producing 7.5Kg-12kg of various specifications of
magnesium ingots and magnesium alloy ingots;
5. One set of environmentally friendly desulfurization and dust removal systems, meeting
the requirements for dust removal, purification, and environmental emissions of
magnesium ingot refining production line;

4.2.4.2 Magnesium alloy refining production process flow:

raw magnesium ingredients—melting—refining/slag

removal—stirring/purifying—components analysis(qualified) -- Automatic quantitative
casting of magnesium ingots-- packaging and storage
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4.2.4.3 Main technical parameters:

The 3T thermal storage gas refining furnace adopts an air single thermal storage type with 4
pairs of energy-saving thermal storage burners, while the solvent furnace (or recovery furnace)
adopts an air single thermal storage type with 2 pairs of burners;

1) Each refining furnace adopts one pneumatic four-way directional valve, while solvent
furnace and recovery furnace use two four-way directional valves
Valves (i.e. 6 sets of two position four ventilation directional valves);
2) Each furnace is equipped with an independent exhaust gas induced draft fan and one
air blower;
3) The air, exhaust gas, and natural gas pipelines, as well as their corresponding pipe
supports, enter the main flue (exhaust temperature 150-180 ℃) after passing through the
induced draft fan for each furnace's exhaust gas, it enters the desulfurization tower and is
finally discharged through the chimney ;
4) Adopting air thermal storage combustion, PLC automatic directional control system and
temperature automatic detection;
6) The gas automatic reversing adopts an electrically controlled quick cut valve;
7) Each furnace is equipped with an ignition nozzle and a control room button for ignition.
The nozzle comes with flame detection, which automatically cuts off the gas supply if the
ignition is unsuccessful or extinguished, ensuring high safety;
8) Each refining furnace (including solvent furnace and recovery furnace) is equipped with
smoke exhaust thermocouples and various smoke exhaust temperature patrol
inspections;
9) Each refining furnace (including solvent furnace and recovery furnace) is equipped with
one temperature (furnace temperature) thermocouple;
10) Set parameters in the electrical control room for easy operation.

4.2.4.3 Main equipment parameters of the refining system:

A: Thermal storage gas refining furnace:

1. Main technical parameters:

No Item unit data

1 Circular furnace type Energy saving thermal storage refining furnace
Refining furnace inner 1950
2 mm
diameter
3 High inside the refining furnace mm 2250
4 Refining furnace outer dia. mm 3150

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 5 Furnace temperature ℃ 900--1000
6 Fuel type NG
7 Low heating value of fuel Kcal/Nm3 LHV～8500
8 Maximum fuel consumption Nm3/h ～120
9 Maximum air consumption Nm3/h ～1260
10 Burning method Air thermal storage combustion
11 Heating method Side heating
12 Air preheating temperature ℃ ≥900
13 Smoke exhaust temperature ℃ ～150
14 Reversing method Two position four-way directional valve
15 control mode PLC control
16 Crucible size mm Ø 1200×2050
17 Single furnace melting Cap. 3.5t Magnesium liquid
Smoke exhaust method Thermal storage positive pressure+ forced
18
smoke exhaust with induced draft fan

2. Brief description of structural characteristics:

The heat storage refining furnace is a circular chamber heating furnace with a working
temperature of 900-1000 ℃. This scheme uses natural gas as fuel and adopts a preheated
high-temperature air heat storage combustion with air single heat storage. The burners are
symmetrically arranged. The advantages of thermal storage refining furnaces are mainly
manifested as:
2.1. Adopting efficient extreme heat recovery technology, the air is preheated to 900 ℃.
The use of thermal storage combustion technology can utilize the waste heat of flue gas to
almost the limit, recover the latent heat of flue gas to the maximum extent, and preheat
both air and gas to a temperature close to the furnace gas. The exhaust gas temperature
can be lower than 120 ℃, greatly improving the waste heat recovery rate and significantly
reducing energy consumption;

2.2 The temperature inside the furnace is uniform, with no local high temperature points
and low oxidation burn loss. The combustion under high-temperature and oxygen poor
conditions produces a uniform high-temperature reaction, forming diffuse combustion
products that can evenly fill the entire combustion space, making the furnace temperature
uniform. This can improve the product quality of the furnace, extend the furnace life, and
greatly improve the service life of the refining pot, reducing the cost of magnesium alloy
refining (melting process);

2.3 Compared to the current general magnesium metal refining furnace, it can save more
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than 30% of energy, enhance heat transfer, and increase production. Flame stability is
different from traditional diffusion flames. Under high temperature (higher than the self
ignition temperature of the fuel) preheating air conditions, as long as the fuel diffuses,
mixes, and enters the combustible range (the combustible range is greatly expanded),
combustion will occur spontaneously without the need for a flame stabilization
mechanism, thus ensuring stable combustion.;

2.4 Adopting a PLC with reliable performance for reversing and combustion systems;
Adopting flexible and protective control methods; PID automatic temperature control,
improving melting speed and settling time;
Reducing the emissions of harmful gases such as NOx and CO by

2.5 can significantly improve the on-site production environment. In order to reduce NOx
emissions during high-temperature combustion, regenerative combustion and waste heat
recovery technologies use the method of reducing the concentration of oxygen in the
combustion space to create conditions for lean oxygen combustion. Reduce environmental
pollution. The regenerative combustion technology not only saves energy and reduces
smoke emissions, but also greatly reduces the content of harmful gases such as NOx in the
smoke, reducing environmental pollution.

2.6. Combustion and piping systems:

1) The pipeline system consists of an automatic pressure measuring device, an

emergency shut-off valve, and a manual valve. In case of gas underpressure and
overpressure, fan failure, and emergency power outage, the gas source will be
automatically shut off and an alarm will be triggered. Ensure safety.
2) The temperature control adopts PID digital intelligent temperature control
instrument and PLC programmable controller to automatically control the
temperature. The temperature control is continuously adjustable, with over
temperature alarm and safety protection measures for leakage, short circuit, overload,
overcurrent, undervoltage, etc., to ensure long-term stable operation of the system
and achieve fault free operation.
3) Using a PLC system for centralized control of the combustion system, automatically
completing the reversing action of the reversing valve and controlling the interlocking
action of each reversing valve. Ensure the safe and reliable operation of the
combustion system.
4) Using ceramic honeycomb thermal storage material, the combustion air adopts
secondary input, and the high-temperature preheating combustion air mixes strongly
with the fuel in the burner brick. Incomplete combustion occurs due to insufficient air
volume. Expanded the flame combustion area, reduced temperature dead angles, and
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 made the furnace temperature more uniform. Realizing low oxygen combustion
reduces the emissions of nitrides and carbon dioxide. The energy-saving and
environmental protection effect is excellent.
5) Distributed control is achieved through a high-performance and highly reliable PLC
control system, equipped with a high-performance intelligent digital temperature
controller. Accurate temperature control and high degree of automation.
4.2.5 Retort(tank) making and maintenance workshop

The reduction tank in the reduction furnace is a vulnerable component with high annual
consumption. A can making and maintenance workshop is specially set up for the production
and maintenance of the reduction tank, as well as the maintenance and use of other
equipment.
1. Calculation of can production capacity:

The service life of the reduction tank is 60 days, with an annual working time of 330
days. The total number of reduction tanks is 288, and the calculated annual usage of
reduction tanks is 1584;

The production capacity of the can making workshop is calculated at 1.2 times, with a
production capacity of 1900 units per year;

Therefore, the production capacity of the can making workshop is designed to be

1860 units per year.

2. Selection of electric furnace capacity

The size of the straight section blank of the reduction tank is Φ 630X50X4040, can
weight 2890kg; The weight of the cone end blank is 220kg, and the splashing during
the casting process is considered at 3%, resulting in a total weight of 3203kg of molten
iron;

Therefore, a capacity of 3.5 tons of electric furnace is selected, and considering the
heating time of the electric furnace, 2x 3.5 ton electric furnaces are selected,
including one for heating and one for insulation, using one set of power supply. Ability
to achieve 1 tank per hour.

3. Energy consumption

• The total installed capacity of the can making and maintenance workshop is
3600KW, including 3200KW for high voltage (11/6.6kV) and 400kW for low
voltage (400V);

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 • Compressed air: 5 m3/min
• Water: 0.1 liters/hour
• Argon gas: 40 liters/1000 spectral analysis

4.2.5.1 Melting section

A. Overview of Production Process

Add waste stainless steel materials or new heat-resistant steel ingredients to the medium
frequency furnace for smelting, start feeding and add lime, fluorite and scrap steel at the
bottom of the furnace, then add the recycled materials to start the medium frequency furnace.
During the melting process, carefully observe the current, voltage and water path, and tamp
and add materials to aid melting. Gradually add slag forming materials.

After the recycled materials are melted, the temperature of molten steel rises to 1480 ℃
-1520 ℃, and then extract slag for sampling, and make new slag and adjust the slag to foam
slag, After the pre furnace sample is produced, materials such as Cr and Ni will be added based
on the analysis results. The indicators reach around Cr ≥ 25, Ni ≥ 7-8.5, Si: 1.6-1.7, Mn: 0.65-0.8,
N: 0.2-0.3, S: 0.04, P: 0.04. After the supplementary material is melted, start adding silicon
calcium for deoxygenation, with a deoxygenation time of 8-10 minutes; Until the shrinkage
sample shows small shrinkage pores, when the temperature rises to 1560 ℃ -1580 ℃, treat
the slag and add 1.5-2kg of rare earth to adjust the slag to a thin level.

Lift the intermediate frequency furnace top through the hydraulic system and pour the molten
steel into the ladle; And lift it to the fixed position of the centrifugal casting system; By using a
high-speed roller centrifuge and utilizing good centrifugal force, it can be cast at a certain
number of revolutions φ 630 × 4000mm magnesium reduction tank.

Use metal grinding tools to cast the conical tube part.

1. Raw material indicators
1) Fluorite: particle size 1-2cm, CaF ≥ 92%
2) Waste carbon steel: steel content ≥ 95%
3) Lime: particle size 2-4cm
4) Stainless steel return to furnace material: Ni ≥ 6.7%, Cr ≥ 23%.
5) Quartz sand: particle size 20-40 mesh, impurity content ≤ 2%, moisture content
1.5 ‰

3. Composition standard for molten steel, (for reference only, subject to final actual
requirements):

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content Cr Ni Si Mn N C S P Fea

standard ≥25 ≥7-8.5 1.6-1.7 0.65-0.8 0.23-0.27 <0.38 <0.04 <0.04 residue

4. Process and technical parameters

1) Main pipe diameter range: Ф 630mm

2) Casting can length range: 4000mm

4.2.5.2 Magnesium tank centrifugal casting machine

A. Equipment model and technical requirements;

• Equipment model: FLM-II
• Execution range of maximum outer diameter of cast pipe: Ф 630mm
• Maximum cast pipe length: 4000mm
• Main motor: (110KW variable frequency speed regulation motor -1 unit)
• Total electricity consumption: 125KW
• Floor area: 19.3 meters × 5 meters, maximum height of equipment 1.6 meters
• Production rate of cast pipes: about 1 pipe/h
• Labor force: 2 people/shift
• Maximum rotating weight of equipment: 13T (including cast iron and rotating parts)
• Maximum cylinder speed: 0-700r/min continuously adjustable
• Roller specifications: Ф six hundred and twenty × 200mm
• Maximum speed of the supporting wheel: 960 rpm

B. Centrifuge composition:
The equipment mainly consists of a host, pouring components, a winch, sand delivery and
discharge pipe components, an electrical control system, and so on.
1. The host mainly includes: supporting wheel group, large floor, middle bottom plate,
supporting wheel seat, and host protective cover.
2. The pouring components include: a chute car and a set of car guide rails.
3. The sand delivery and pipe components include: the body of the sand delivery and pipe
delivery car, the sand delivery pipe, the sand delivery support wheel, the takeover support
wheel, and the horizontal track of the car.
4. Electrical control cabinet -1 set

C. Structural performance characteristics

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 1. Host
The main engine rotation is driven by a 110KW variable frequency speed regulation motor
combined with a frequency converter, which can achieve low-speed start and high-speed
constant rotation. Different proportions of pulleys can enable the maximum rotation
speed of the large pipe mold to reach 700rpm.
The combination of independent driving and driven wheels makes the adjustment of the
main engine faster and more convenient, and the weight of the pipe mold overcomes the
stall caused by the rotation of the pipe mold.

2. Chute car
The walking design of the chute car is manual.

3. sand delivery and pipe discharge trolley

The walking motion of the horizontal sand delivery and takeover trolley is manual
Both the sand feeding roller and the connecting roller are equipped with radial ball
bearings to ensure that each roller can rotate flexibly.

4. Electrical control system

The host controls the centrifugal machine's start-up, rotation, and deceleration processes
through a variable frequency speed controller.
The electrical cabinet is equipped with input voltage, current, output voltage, and current
indicators. The control panel is equipped with a motor speed display. Install emergency
stop switches, fault indications, etc.

5. Lubrication system
The main engine support wheel seat is equipped with a lubrication system, and the top is
equipped with an oil filling port. Lubricating fluid is added once per shift. Check and add
gear oil to each gearbox every three months.

4.2.5.3 Other parts

In addition to electric furnaces and centrifuges, the can making and maintenance workshop is
also equipped with auxiliary equipment such as processing and metering,
1. Casting metal molds for casting the lower cone end of vertical tanks;
Using metal molds, painting, and hand casting to form.

2. The lathe is used to process the blank of vertical cans;

• The lathe specification is:
• Model: CW6180-5m
• Maximum turning diameter on the bed: 800mm
• Maximum workpiece length: 5m
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 • Spindle inner hole diameter: 104mm
• Maximum turning length: 4850mm
• Main motor model: Y160M-4
• Main motor power: 11kw
• Cooling electric pump power: 90w
• Cooling electric pump flow rate: 2.5L/min
• Machine height: 1450mm
• Machine width: 1380mm
• Machine length: 7200mm
• Machine weight: 8 tons

3. The airtight testing machine is used to detect the welding effect of the weld seam
• Diameter of pressure test piece: 630mm
• Test piece length: 4500mm
• Pressure test: 0.12MPa

4. Measuring scales are used for measuring electric furnace materials

• The hook scale is installed on the hook of the crane and is used to weigh heavy items
weighing 0-5t;
• Desktop scales are used to weigh other items weighing less than 100kg;

5. Spectral analyzer is used for rapid analysis of the composition of molten iron;
• Mainly for rapid analysis of elements such as Cr, Ni, Si, Mn, N, S, P, etc;
• Model: CCD 6500

6. Temperature measuring gun

Used to detect the temperature of molten iron, temperature measurement range: 800-1800 °
C

7. Lifting equipment
7.1 Metallurgical crane, used for lifting iron ladle and pipe mold.
• Model: QDY16/3.2-12
• Lifting capacity: 16t
• Lifting height: 12m
• Span: determined based on detailed design
• Work system: A7
• Total motor power: 54kw;
7.2 electric single beam crane, used for lifting ordinary parts.
• Lifting weight: 10t
• Lifting height: 12m
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 • Work system: A5
• Total motor power: 9kw;

8. Welding equipment
Used for welding the conical end of the reduction tank, using manual welding method;
• Equipment selection: ZX7-500 Quantity: 2 units
• The technical parameters are as follows:
• Rated input voltage: AC380
• Rated input capacity: 25KVA
• No load voltage: 75V
• Input current regulation: 20-500A
• Rated working voltage: 40V
• Thrust adjustment: 0-100A
• Load duration: 60%
• Efficiency: 85%
• Power factor: 0.93
• Net weight: 18.6kg
• External dimensions: 530mmX270mmX465mm

9. Transportation equipment
The cross span transportation equipment adopts electric flatbed trucks with a rated load
capacity of 15 tons and a quantity of 1 unit. The specific parameters are as follows:
No. Parameter Name Parameter values Unit

1 Maximum load capacity 15 t

2 running speed 30 m/min
3 Motor power 5.5 Kw
4 Track inner distance 1435 mm
5 Maximum wheel pressure 4 t
6 Platform size 4500*2200 Table height : 750 mm
7 Wheel diameter φ500 mm
8 Transportation distance ~ 40 m
9 Recommended track model P43Kg
control mode Remote control + onboard
10
control
Power supply method End synchronous cable drum
11
power supply

10. Screening equipment

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The screening equipment is used for screening quartz sand for centrifugal casting, and
DZSF520 vibrating screen is selected

The vibrating screen screening machine is driven by dual vibration motors. The motion
trajectory of the screening machine is a straight line. The two motor axes have an inclination
angle in the vertical direction relative to the screen surface. Under the combined force of
excitation force and material self gravity, the material is thrown up and jumps or moves
forward in a straight line on the screen surface, thereby achieving the purpose of screening
and grading the material. Suitable for screening various dry powder or granular materials with
a particle size of 0.074-5mm, a moisture content of less than 7%, and no viscosity.

The particle size of the large feed shall not exceed 10mm. This product has high screening
accuracy, large processing capacity, simple structure, low energy consumption, low noise, long
service life of the screen, good sealing, no dust overflow, and convenient maintenance.

The DZSF520 small feed vibrating screening machine is a small and medium-sized model of
feed vibrating screening equipment. The equipment is 500mm wide, 2000mm long, and has a
motor power of 1kw; The characteristics of high screening accuracy, large processing capacity,
and simple structure.

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Chapter 6 - Electrical and Automation

6.1 Design scope

This project is an annual production line of 14200 tons of magnesium, which includes
transformer and distribution, workshop power, electrical control and lighting, lightning
protection, grounding, etc., from raw materials entering the factory to finished product
packaging leaving the factory. The electrical design is based on the conditions provided by the
process and other specialties, as well as the relevant electrical data provided by the factory.

6.2 Power supply and distribution system

6.2.1 Power supply and distribution

1. Power supply and main step-down station
The power supply will be provided by The Client with a dual circuit 11KV power supply line to
the factory area. Due to the large total installed capacity of this project and considering the
second phase project, it is recommended to set up a 11kV main step-down station in the
factory area.

The incoming voltage of the 11kV main step-down station is 11kV. After the dual circuit power
supply line enters the factory, a 11kV main step-down station is planned to be built in the
middle of the factory area. After the voltage is reduced, it will supply power to various
electrical rooms and high-voltage motors in a 6.6kV radial manner, while reserving power
distribution for the second phase of the project. The power consumption of low-voltage
electrical appliances is planned to be supplied by transformers installed in each electrical room
after voltage reduction.

2. Technical indicators
a. Production system installed capacity: 12,000 kW
• Among them: High voltage motor: 1,810kW
• Low voltage motor: 10,190kW
b. Natural power factor: 0.7
c. Power factor after compensation: 0.95

3. Voltage at all levels

• High voltage motor voltage: 10 kV
• Low voltage distribution voltage: 0.66kV/0.4kV/0.23kV
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 • Low voltage motor voltage: 400V
• Lighting voltage: 220V
• Maintenance lighting voltage: 24V
6.2.3 Workshop power distribution and electric drive

1. Electrical room and high-voltage distribution

According to the load distribution of the production line and the process layout plan, six
electrical rooms are set up.
1. The electrical room of the refining workshop is equipped with a low-voltage
distribution room, a transformer room, and a transformer with a model of
S13-M-1000KVA/10/0.4KV, which supplies power to the low-voltage load electricity
unit of the refining workshop.
2. The calcination dolime production electrical room (central control room) is
equipped with high-voltage distribution room, low-voltage distribution room,
transformer room, transformer room, central control room, etc. The high-voltage
distribution room supplies power to the kiln tail fan, 6.6kV high-voltage motor, and
transformer. There is a transformer in the transformer room, with a model of
S13-M-800KVA/10/0.4KV, which supplies power to low-voltage loads such as the
calcination production line, waste gas treatment, preheater, and cooling machine.
3. The electrical room of the grinding and pressing ball workshop is equipped with
high-voltage distribution room, low-voltage distribution room, transformer room,
etc. The high-voltage distribution room supplies power to the 6.6kV grinding motor
and transformer, and a transformer with the model S13-M-800KVA/10/0.4KV is
installed in the transformer room to supply power to the low-voltage load of the
grinding pressure ball workshop.
4. The electrical room of the restoration workshop is equipped with a high-voltage
distribution room, a low-voltage distribution room, and a transformer room. There
are two transformers in the transformer room, with the transformer model
S13-M-2000KVA/10/0.4KV, which respectively supply power to the low-voltage
load of the reduction workshop.
5. The electrical room of the tank making and maintenance workshop is equipped
with a high-voltage distribution room, a low-voltage distribution room, and a
transformer room. There are two transformers in the transformer room, with the
transformer model S13-M-2000KVA/10/0.66KV, which respectively supply power
to the induction furnace and other equipment.
6. The electrical room of the utility system is equipped with a low-voltage distribution
room, a transformer room, and a transformer with a model of
S13-M-1600KVA/10/0.4KV, which supplies power to the low-voltage load units of
the circulating water and air compression station system.
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2. Power factor compensation
The reactive power compensation of this project adopts the scheme of installing low-voltage
capacitors for automatic compensation in each electrical room, and installing single machine
on-site compensation for high-voltage motors.

3. Electrical measurement
Install corresponding measuring devices in each electrical room according to the specifications,
such as kilowatt hour meters, voltmeters, ammeters, power factor meters, etc., to monitor the
load changes of the entire plant and each electrical room.

4. Production line power supply and distribution lines

The factory area supplies power to each electrical room in a 6.6kV radial manner, and the
low-voltage electrical equipment in the workshop is supplied by each electrical room in a
combination of 400V, 660V radial and chain forms.

6.3 Automation control system

6.3.1 Design Principles and Plans

In order to make the production process in the best operating state, ensure product quality,
save energy, improve labor productivity, and realize management modernization, the project
adopts DCS distributed control system with advanced technology and reliable performance to
realize centralized, segmented operation, monitoring, management, and decentralized control
of the entire production line.

6.3.2 DCS system configuration

The DCS system consists of three parts: on-site control station, high-speed data network, and
operation station. From the perspective of its process flow, the entire factory can be divided
into several parts: calcination production, grinding and pressing of balls, magnesium reduction,
refining of magnesium processing, tank making and maintenance workshop, as well as
auxiliary facilities such as air compressor station and circulating water system.

According to the production process characteristics of each process, the control system of the
entire factory can be divided into calcination production control system, grinding ball control
system, magnesium reduction control system, refined magnesium processing control system,
can maintenance workshop and its auxiliary facilities control system (including air compressor
station control system and water circulation control system), each system is independent and
coordinated with each other. To control the entire production line. The entire factory is
equipped with a central control room, and the operation stations in the central control room
complete the sequential logic control of process equipment and the detection, adjustment,
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and alarm of process parameters through the on-site control station.

There are five on-site control stations, five operation stations, and one programming station in
the entire factory. The high-speed data network uses fiber optic cables to form industrial
Ethernet. The can making maintenance workshop does not enter the DCS system

6.3.3 Scope of on-site control station

The on-site control station completes the sequential logic control of process equipment
motors, monitors process parameters, and automatically adjusts process circuits. It also
communicates data with the operation station in the central control room and other on-site
stations through a communication network.

The on-site control station is located in the calcination production electrical room (central
control room), with control scope covering calcination screening and transportation, batching,
preheating, kiln system calcination, waste gas treatment, cooling transportation and storage.

The on-site control station is located in the electrical room of the grinding and pressing ball
workshop, and controls the batching and conveying of grinding and pressing balls into balls
according to process requirements.

The on-site control station is located in the electrical room of the reduction workshop and
completes the following tasks according to the process requirements: temperature closed-loop
control of the reduction furnace, vacuum closed-loop control, furnace front display, and alarm
control.

The on-site control station is located in the electrical room of the refining workshop to
complete the processing of magnesium ingots.

The on-site control station is located in the electrical room of the water pump room to
complete the control of the Utility system.

The on-site control station is located in the can making and maintenance workshop, mainly
responsible for centrifugal casting of reduction tanks and equipment maintenance.

6.3.4, Operation Station

The operation station is located in each electrical room and central control room. There are
five operation stations and one programming station in the entire factory, which correspond to

1 # on-site control station,

2 # on-site control station,
3 # on-site control station,
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 4 # on-site control station,
5 # on-site control station.
The main functions are: displaying the motor start stop operation and operating status on a
process flowchart with dynamic parameters, displaying the historical trend curve of process
parameters, detailed display of the adjustment circuit and modification of operating
parameters, displaying alarm status, printing alarm reports and process reports, monitoring
and alarming the DCS system status.

6.3.5, Application Software

DCS system application software is important software that connects the on-site control
station and operator station. It needs to be developed and debugged based on a clear
understanding of the production process and DCS system software and hardware
characteristics.
1) Logic control software
For all motors and solenoid valves on the process line, according to the flowchart
displayed on the operation station, the motor can be started, stopped, single machine
started, stopped, emergency reset, and logic interlocking can be completed through
keyboard and mouse operations.

2) Process control software

The circuits for automatically adjusting process parameters include:
• Adjust the speed of the high-temperature fan at the kiln tail based on the negative
pressure control at the preheater outlet.
• Control and adjust the amount of natural gas according to the inlet temperature of
the preheater.
• Adjust the valve opening of the kiln exhaust fan according to the negative pressure
of the kiln.
• Adjust the natural gas and air valve opening according to the temperature of the
reduction furnace.
• Adjust the vacuum solenoid valve and vacuum pump according to the vacuum
situation inside the reduction furnace.
• Adjust the natural gas and air valve opening according to the temperature of the
refining furnace.

6.3.6, Setting of Special Instruments

1) Quality control system for ingredients: In order to ensure the quality of calcination and
the balance and stability of the pressure ball, high-precision static metering batching
scales and corresponding QCS quality control systems are selected to optimize the control
of material accuracy and quality. The system includes ingredient metering equipment,
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 speed control feeding equipment, computer, external equipment, and corresponding
software.

2) A CO gas analysis device is installed at the inlet of the kiln tail dust collection, and a CO
and 02 analysis device is installed at the outlet of the secondary cylinder. The system
includes gas sampling probes, pre-treatment cabinets, analysis devices, etc.

3) An infrared dual color high-temperature instrument is installed for the temperature

detection of the kiln firing zone and the discharge temperature.

4) A fire watching television is installed at the kiln head.

6.3.7, Factory Management

Install a complete computer monitoring system in the management office, which is connected
to the entire plant DCS system through communication. It can help management personnel to
command production in a timely and accurate manner.

Management personnel can also use this system to understand various information about the
current and process production of the entire factory, such as querying the storage and
consumption of raw materials, equipment operation status, recent production and quality
status, etc.

6.3.8 Equipment selection

1) The temperature instrument adopts armored Pt100 thermistor and armored K-type
thermocouple.

2) Select imported or imported products for pressure, differential pressure, and flow
transmitters.
3) The level detection instrument can be selected according to different purposes, using
either a heavy hammer level gauge or a resistance rotation level gauge.

6.3.9, Cable Selection

1) The connection wires and DC signal wires between the transmitter and various on-site
stations for a single detection component are all made of KVVP type multi core shielded
copper core cables with sheaths. KVV copper core cables are selected for communication
and switching signals. Thermocouples are equipped with high-temperature compensating
wires with shielding and sheathing.

2) The connecting cables and wires between various equipment in the DCS system are

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 supplied as a complete set with the equipment.

6.3.10, Cable laying

The cables between the primary components and the on-site station are buried in pipes or laid
along cable trays. The cables inside the control room are laid under raised indoor floors, and
the main communication cables are laid in outdoor cable trays.

6.3.11, Grounding protection

The quality of the grounding system is crucial for the anti-interference of automation facilities,
and grounding devices are installed separately at each on-site station. The shielding layer of
the signal cable is connected to the shielding grounding device at one end of the box. The
grounding of computer systems shall be carried out in accordance with the requirements of
each equipment manufacturer. The metal casing of the instrument panel is connected to the
electrical protection grounding bus.

6.3.12, Instrument Repair

Install an instrument repair room in the central control room to complete daily maintenance
and repair of instruments and computer systems.

Chapter 7 - Utility Systems

7.1 Design scope

The Utility system of this project mainly includes the following systems:
(1) Circulating water system
(2) Fire protection system
(3) Compressed air system
(4) Nitrogen system
Due to the construction site of this project being in Oman, the fire protection system is
designed and constructed by The Client uniformly, and will not be described in detail here.
Other systems, as they involve production, are detailed below.

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7.2 Circulating water system

7.2.1 Water source

The production and daily water use of this project shall be the responsibility of The Client to
divert water or drill wells at the construction site as the water source for this project.
The factory is equipped with facilities such as reservoirs, circulating water tanks, and water
treatment systems, and the water supply capacity of the water source should meet the needs
of the factory.
Standard code Water quality（mg/L） Remark
item Based on CaO Based on CaCO3 Drainage ℃
Calcium ≤140 ≤250 45
GBJ29—90 carbonate 168 330 40
hardness 196 350 35
280 500 30

7.2.2 Production water consumption

Circulating water volume in calcination, grinding, and briquette workshops: 56 × 24= 1,344
m³/D, reduction, refining workshop circulating water volume: 1152 × 24=27,648 m³/D, the total
amount of circulating water for production is 28,992 m³/D. Based on a 0.4% evaporation rate,
the daily water consumption, for production in this project, is 115.97 m3.
This project sets up a laboratory with a water consumption of generally 12~15 m ³/ D
The total water consumption for production is:
115.97+15=120.97 m³/D.

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7.2.3 Domestic water consumption
The project has a staff of 280 people, including 260 production workers and 20 laboratory
workers.
According to the labor quota water volume standard, it is 50L/person/day, and the daily living
water volume is 14m3; The water consumption of public bathrooms is 20 L/person · day, and
the daily water consumption of bathrooms is 5.6m3. According to the above, the total
domestic water consumption of this project is 19.6 m3.

7.2.4 Unforeseeable water

Calculated based on 10% of the total water consumption, the water consumption is
(19.6+120.97) × 10%=14.06m3/d.

7.2.5 Total water consumption

According to the above calculation, the total daily water consumption of this project is
120.97+19.6+14.06=168.69m3/d. (Due to the correlation between evaporation and
surrounding temperature environment, generally considering 0.4-1%)

7.2.6 Fire water supply

The fire resistance rating of the factory building is Level 2, and the fire hazard is Class C. The
number of fires in the factory area at the same time is calculated as one. According to the
"Code for Fire Protection Design of Buildings" GB50016-2006, the indoor fire water
consumption is 15L/s, the outdoor fire water consumption is 25L/s, the fire duration is 2 hours,
and the total fire water consumption is 288 m3. A fire water tank and pump room are set up in
the factory area. And two fire water pumps will be installed in the pump room, one for use and
one for backup.

7.2.7 Circulating water tank, water pump room

According to the layout of the overall process plan and the distribution of various water
consumption points, a circulating water tank and a water pump room are set up in the middle
of the production area in this project, radiating to each water consumption point through
pipelines.

Two fire water pumps with a flow rate greater than 180 m³/h are installed in the water pump
room. Variable frequency speed regulation and head guarantee the water pressure of all
fire-fighting facilities. Seven circulating water pumps are installed, of which five (four in use
and one as backup) have a flow rate of 300 m³/h. Dedicated for use in the restoration
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workshop, two units (one for use and one for backup) with a flow rate of 100m³/h. For use by
other water points. At the same time, dosing facilities, electrical rooms, and duty rooms are set
up in the circulating pump room.
The water tank adopts a semi underground structure, with a storage capacity of 300m³ for the
fire water tank. The water demand of the circulating water tank is greater than 1000m ³。 A
cooling tower is installed on the upper part of the circulating water tank to cool down the
circulating water.
Central control, laboratory and other auxiliary facilities room the indoor water supply pipe
adopts PP-R pipe with hot melt connection; The outdoor water supply pipeline and production
workshop adopts steel water supply pipes with socket connections.

Here is Cooling water quality standard

Item unit value
turbidity NTU ≤20.0
PH value (25°C) 6.8～9.5
Calcium hardness + full hardness
mg/L ≤1100
(based on CaCO3)
Total Fe mg/L ≤2.0
Cu2- mg/L ≤0.1
CL mg/L ≤700
SO42-+CL mg/L ≤2500
Silicic acid (as SiO2) mg/L ≤175
Free chlorine mg/L 0.1～10
NH3-N mg/L ≤10
Petroleum kind mg/L ≤5.0
COD mg/L ≤150

7.3 Compressed air and nitrogen system

Compressed air is mainly used for backflushing of dust collectors and various pneumatic valves.
According to the operation of the process equipment at full load, the total gas consumption is
49.6m3/min, and the gas pressure is 0.5-0.7MPa.

This new construction project requires the construction of a new air compression station,
where compressed air is sent to various gas consumption points through a micro heat
adsorption dryer, two-stage oil removal, water removal filter, and pipeline for use.

There are three 50m3/min screw air compressors and one 15m3/min nitrogen generator
installed in the air compression station, with one air compressor used at each gas consumption
point on the production line of this project; One air compressor is used for nitrogen production,
and one air compressor is standby. The nitrogen generator is equipped with a 20m3 nitrogen
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storage tank for safety protection of natural gas pipelines and use in refining workshops.

If the owner's 44m3/min compressor can be matched with a 15m3/min nitrogen generator, it
can be replaced accordingly.

7.4 Laboratory

A central laboratory is set up in the factory area, responsible for routine chemical analysis of
incoming and outgoing raw materials, fuels, semi-finished products, and finished products, to
ensure the quality of products in all production processes of the factory, and to schedule,
manage, and supervise the quality of lime products.

Considering the impact of long-distance transportation and policies, the laboratory equipment
for this project only provides the following equipment. Other reagents and containers will be
purchased locally by the client:
Unified experimental small mill SM05 500×500mm set 1
Computer sulfur analyzer 5E-8S,CLS-3000 set 1
Multifunctional heat meter CT7000,5E-1AC,FRL-3000 set 1
Stainless steel electric distilled
20L／H set 1
water heater
High temperature box type
SX2-4-10 set 2
resistance furnace
Electric blast drying oven 101C 450×550×550mm set 2
Electronic balance 200g d:0.1mg set 2
Fiberglass fume hood SZB-3 set 2
Crusher FJ-100 set 1
Gimbal balance JP-A 1000g set 2
Adjustable universal electric
KD-1 set 1
furnace
Drug cabinet 1200×400×180mm pcs 4
Platform scale 10kg, division 50g set 1
Thermostatic magnetic mixer 78HW-1 set 1
Timed electric mixer JJ-1 set 1
Water sieve 125×80mm, aperture0.08mm set 1

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