MagnesiumMagnesium’s remarkable stiffnessStiffness-to-weight and high strengthStrength-to-weight ratios could enable substantial vehicle lightweighting versus aluminum and steel. However, primary production is very energy- and emissions-intensive, and recyclingRecycling cannot cost-effectively produce magnesiumMagnesium of sufficient purity for die casting and other structural applications. Distillation can produce high-purity magnesiumMagnesium but is capital- and energy-intensive. Gravity-Driven Multiple Effect Thermal System (G-METS) is a continuous low-pressure magnesiumMagnesium distillation process used in primary production or recyclingRecycling in which heat re-use leads to just 0.5–1 kWh energy consumption per kgMg Mg product—which is 80–90% less energy than current Mg distillation. This paper presents new partial distillation experiments showing 99.96% product purity. An industrial distiller design can help to estimate capital costs. New modeling work describes temperature and pressure change in the vapor conduit, energy use and losses in the industrial distiller, and effects of evaporator flow vanes on the separation of volatile elements such as zinc.