The electrode potentials of magnesium, manganese, and aluminum were measured in various mixtures of the binary electrolyte: NaCl: MgCl2 within the temperature range 680 to 740degreesC. An electrochemical series was established consisting of (in order of increasing electropositivity) aluminum, manganese, and magnesium. Manganese and magnesium were well resolved but aluminum and manganese were only resolved by similar to60 mV. Electrorefining experiments using a simple cell were based on the above salt mixture and 98 wt % of magnesium and 26 wt % of manganese were removed from the alloy: AlMg2.73Mn0.4. By introducing aluminum ions into the salt (similar to10 wt %) the Al/Al3+ electrode potential was increased, thereby assisting manganese separation. Results from experiments using a novel recessed-channel cell (RCC) removed 99 wt % of magnesium and 46 wt % manganese from molten used-beverage can alloy: AlMg1.0Mn1.2 and 70% removal of manganese from the alloy: AlSi1.0Mg0.8Mn0.7. The RCC conferred many advantages over conventional electrowinning cells, namely very low energy consumption, highly efficient mass transfer of metal cations, high current densities, and no pollution or wasteful by-products. A substantial throughput of liquid alloy was achieved with minimal energy consumption (1.6 kWh kg(-1)) and high current densities (similar to10700 Am-2 based on similar to50% liquid coverage) with magnesium being deposited on the cathode and with appropriate process control Al:Mg master alloys may be formed in situ. (C) 2003 The Electrochemical Society.