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Developments in synthetic magnesia production Paul Schipper, Managing Director Nedmag Industries.

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Presentation on theme: "Developments in synthetic magnesia production Paul Schipper, Managing Director Nedmag Industries."— Presentation transcript:

1 Developments in synthetic magnesia production Paul Schipper, Managing Director Nedmag Industries

2 Nedmag Market leader in synthetic DBM

3 Nedmag Product Range nedMag 99 high purity synthetic DBM oxide Important raw material for refractories for the cement and steel industry nedMag C Magnesium Chloride solids & solutions Used in a wide range of applications, from industrial processes like textile finishing and catalyst production to the production of feed and food additives Nedmag is a competitive and reliable supplier of de-icers throughout the world Due to its very hygroscopic character, it is one of the most effective dust suppressants nedMag Ca Calcium Chloride solids & solutions Used in drilling mud in oil & gas industry, as dehydration agents, as dust suppressants, as de-icers Effective de-icer used for melting ice and snow (lowest freezing point), widely used in prewetting salt Effective agent for dust control and has properties making it ideal for maintaining unpaved roads nedMag H industrial grade Magnesium Hydroxide Sold in suspension and in powder form, mainly used in the production of paper coatings, in pulp bleaching, as friendly alkali to neutralize acidic waste water streams and to treat acidic flue gasses

4 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

5 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

6 Natural DBM Process Overview Source: Magnesita

7 Source: Maerz Synthetic DBM Process Overview

8 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

9 In synthetic DBM, the main cost drivers are energy & raw materials, and investments & maintenance Energy & raw materials costs will rise Investments & maintenance costs will rise

10 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

11 Limited Availability of Synthetic DBM versus 10 000 000 t supply of natural DBM Nedmag 165 kt Ube MartinMarietta 40 kt Penoles PPL 85 kt PRODUCERS

12 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

13 Oil price will continue to increase Oil price in US$ per barrel (source: International Energy Agency)

14 Energy-related Investments 1 000 000 EUR per year in Nedmag DBM Production Recent Nedmag Investments € 5 000 000 Optimisation calcining € 500 000 Reduced Hydration € 250 000 Process Automation € 3 500 000 Increased Plant Efficiency € 900 000

15 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

16 Environmental Factors impacting Synthetic DBM Production Synthetic MgO Producers Dust Regulations Emission Regulations (NOx, CO2, SO2) Effluent Regulations Other

17 High Environmental Investments >> 1 000 000 EUR per year in Nedmag DBM Production Recent Nedmag Investments € 7 000 000 Exhaust Gas Scrubbers € 2 900 000 Noise Reduction € 700 000 Dust filters € 3 000 000 Emission Control € 400 000

18 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

19 Consistency Focus on: Technology Raw materials (brine and dolime) Automation Process control Investments over € 1 500 000 per year

20 Consistency:major characteristics very stable over time CaO % < 0,8% every year CaO % in nedMag 99 (yearly average)

21 Consistency:major characteristics very stable over time SiO 2 % < 0,15% every year SiO 2 % in nedMag 99 (yearly average)

22 In cement applications, Nedmag has the best product Very low lime content < 0.9% (to prevent formation of low melting calcium aluminates) Very homogeneous distribution of lime (higher lime content cannot be corrected by higher silica content, because lime silicates are not stable enough to prevent formation of calcium aluminates) High magnesia content 98.5% High density 3.4 (low porosity to prevent infiltration of alkali and of lime from cement clinker)

23 Nedmag is exceptional in Mag-Spinel Bricks due to low lime and high magnesia CaO (%) MgO content (%) Source: Value Added Europe NEDMAG 99 PPL Kümas Extra QMAG HFE Magnesita M30 QMAG Extra QMAG Super Chinese Best DBM Penoles

24 In steel applications, Nedmag product is excellent Very homogeneous High magnesia content 98.5% High C/S ratio > 6 High density 3.44 nedMag product can partially replace fused magnesia in MgOC bricks

25 Choice of synthetic DBM supplier depends on technical requirements, specific to each application Nedmag synthetic DBM especially fit for MagSpinel products in Cement applications, Excellent fit for MagCarbon products in Steel applications

26 Agenda Synthetic versus Natural DBM process -Overview natural and synthetic DBM process -Main cost drivers synthetic DBM process -Overview of synthetic DBM producers Key areas in synthetic DBM processing -Energy consumption -Environment -Consistency and characteristics of synthetic DBM -Capacity

27 Nedmag has increased its capacity to 165 000 t

28 Cement demand will increase by 5 % per year on average Cement demand in billion MT (Source: Cembureau)

29 Steel demand will increase by 4 % per year on average Steel demand in billion MT (Source: World Steel Association)

30 1 Million T Synthetic DBM Capacity Closures CompanyCountryDateTechnologyMT pa Steetley UK1991Seawater100 000 National RefractoriesUSA1994Seawater100 000 Sardamag Italy1994Seawater70 000 PenolesMexico1994Seawater70 000 Shin NihonJapan1995Seawater100 000 BirlaIndia1998Seawater50 000 Asahi GlassJapan1999Seawater30 000 Ube Industries *Japan1990’sSeawater200 000 Martin Marietta *USA1990’sBrine50 000 CogemaItaly2003Seawater50 000 Harbison Walker USA2003Brine100 000 JormagJordan2005Brine40 000 Dead Sea PericlaseIsrael2005Brine40 000 TOTAL1 000 000 * still producing DBM at reduced capacity

31 Future supply-demand for synthetic DBM not balanced? Higher demand for cement and steel Lower supply for synthetic DBM Nedmag studying future capacity expansion

32 Link to movie (repackage movie in 3 minutes)

33 Thank you!


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