Download - Developments in synthetic magnesia production Paul Schipper, Managing Director Nedmag Industries
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Developments inDevelopments in
synthetic magnesia synthetic magnesia
productionproduction
Paul Schipper, Managing Director Nedmag Paul Schipper, Managing Director Nedmag
IndustriesIndustries
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NedmagNedmag
Market leader in synthetic DBMMarket leader in synthetic DBM
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Nedmag Product Nedmag Product RangeRange
nedMag 99 nedMag 99 high purity synthetic DBM high purity synthetic DBM oxideoxide
Important raw material for refractories for the cement and steel industryImportant raw material for refractories for the cement and steel industry
nedMag C nedMag C Magnesium Chloride solids & Magnesium Chloride solids & solutionssolutions
Used in a wide range of applications, from industrial processes like textile finishing and catalyst Used in a wide range of applications, from industrial processes like textile finishing and catalyst production production
to the production of feed and food additivesto the production of feed and food additives
Nedmag is a competitive and reliable supplier of de-icers throughout the worldNedmag 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 suppressantsDue to its very hygroscopic character, it is one of the most effective dust suppressants
nedMag Ca nedMag Ca Calcium Chloride solids & Calcium Chloride solids & solutionssolutions
Used in drilling mud in oil & gas industry, as dehydration agents, as dust suppressants, as de-Used in drilling mud in oil & gas industry, as dehydration agents, as dust suppressants, as de-icersicers
Effective de-icer used for melting ice and snow (lowest freezing point), widely used in Effective de-icer used for melting ice and snow (lowest freezing point), widely used in prewetting salt prewetting salt
Effective agent for dust control and has properties making it ideal for maintaining unpaved Effective agent for dust control and has properties making it ideal for maintaining unpaved roadsroads
nedMag H nedMag H industrial grade Magnesium industrial grade Magnesium Hydroxide Hydroxide
Sold in suspension and in powder form, mainly used in the production of paper coatings, in pulp Sold in suspension and in powder form, mainly used in the production of paper coatings, in pulp bleaching, bleaching,
as friendly alkali to neutralize acidic waste water streams and to treat acidic flue gassesas friendly alkali to neutralize acidic waste water streams and to treat acidic flue gasses
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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Natural DBM Process Natural DBM Process OverviewOverview
Source: Magnesita
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Source: Maerz
Synthetic DBM Process Synthetic DBM Process OverviewOverview
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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In synthetic DBM, the main cost In synthetic DBM, the main cost drivers are energy & raw drivers are energy & raw
materials, materials, and investments & and investments &
maintenancemaintenance
Energy & raw materials costs will riseEnergy & raw materials costs will rise
Investments & maintenance costs Investments & maintenance costs will risewill rise
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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Limited Availability of Synthetic DBMLimited Availability of Synthetic DBMversus 10 000 000 t supply of natural versus 10 000 000 t supply of natural
DBMDBM
NedmaNedmagg
165 kt165 kt UbeUbe165 kt165 kt
MartinMartinMariettaMarietta
40 kt40 kt
PenolesPenoles40 kt40 kt
PPLPPL85 kt85 kt
PRODUCERS
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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Oil price will continue to Oil price will continue to increaseincrease
Oil price in US$ per barrelOil price in US$ per barrel(source: International Energy Agency)(source: International Energy Agency)
020406080
100120140160180200
2000 2005 2010 2015 2020 2025 2030
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Energy-related Investments Energy-related Investments 1 000 000 EUR per year1 000 000 EUR per year
in Nedmag DBM Productionin Nedmag DBM ProductionRecent Nedmag Investments € 5 000 000Recent Nedmag Investments € 5 000 000
Optimisation calcining
€ 500 000
Reduced Hydration
€ 250 000
Process Automation
€ 3 500 000
Increased Plant Efficiency
€ 900 000
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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Environmental Factors Environmental Factors impacting Synthetic DBM impacting Synthetic DBM
ProductionProduction
Synthetic
MgO
Producers
DustRegulations
EmissionRegulations
(NOx, CO2, SO2)
EffluentRegulations
Other
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High Environmental High Environmental Investments >> 1 000 000 Investments >> 1 000 000
EUR per yearEUR per yearin Nedmag DBM Productionin Nedmag DBM ProductionRecent Nedmag Investments € 7 000 Recent Nedmag Investments € 7 000
000000Exhaust Gas Scrubbers
€ 2 900 000
Noise Reduction
€ 700 000
Dust filters
€ 3 000 000
Emission Control
€ 400 000
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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ConsistencyConsistency
Focus on:Focus on:
TechnologyTechnology
Raw materials (brine and dolime)Raw materials (brine and dolime)
AutomationAutomation
Process controlProcess control
Investments over € 1 500 000 per Investments over € 1 500 000 per year year
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Consistency:major Consistency:major characteristics very stable characteristics very stable
over timeover time
0,00,10,20,30,40,50,60,70,80,91,01,11,21,31,41,5
2002 2003 2004 2005 2006 2007 2008
CaO % < 0,8% every year
CaO % in nedMag 99 (yearly average)
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Consistency:major Consistency:major characteristics very stable characteristics very stable
over timeover time
0,00
0,05
0,10
0,15
0,20
0,25
0,30
2002 2003 2004 2005 2006 2007 2008
SiO2 % < 0,15% every year
SiO2 % in nedMag 99 (yearly average)
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In cement applications,In cement applications,Nedmag has the best Nedmag has the best
productproductVery low lime content < 0.9%Very low lime content < 0.9%(to prevent formation of low melting calcium aluminates)(to prevent formation of low melting calcium aluminates)
Very homogeneous distribution of Very homogeneous distribution of limelime
(higher lime content cannot be corrected by higher silica content, (higher lime content cannot be corrected by higher silica content, because because
lime silicates are not stable enough to prevent formation of calcium lime silicates are not stable enough to prevent formation of calcium aluminates)aluminates)
High magnesia content 98.5%High magnesia content 98.5%
High density 3.4High density 3.4(low porosity to prevent infiltration of alkali and of lime from cement (low porosity to prevent infiltration of alkali and of lime from cement
clinker)clinker)
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Nedmag is exceptional in Mag-Spinel Nedmag is exceptional in Mag-Spinel
BricksBricks
due to low lime and high magnesia due to low lime and high magnesia
96,0
96,5
97,0
97,5
98,0
98,5
99,0
0,00,51,01,52,02,5 CaO (%)
MgO content (%)
Source: Value Added Europe
NEDMAG 99
PPL
Kümas ExtraQMAGHFE
MagnesitaM30
QMAGExtra
QMAGSuper
ChineseBest DBM
Penoles
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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
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Choice of synthetic DBM supplierChoice of synthetic DBM supplierdepends on technical depends on technical
requirements,requirements,specific to each applicationspecific to each application
Nedmag synthetic DBMNedmag synthetic DBM
especially fit for MagSpinel especially fit for MagSpinel
products in Cement applications,products in Cement applications,
Excellent fit for MagCarbon Excellent fit for MagCarbon
products in Steel applicationsproducts in Steel applications
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AgendaAgendaSynthetic versus Natural DBM Synthetic versus Natural DBM
processprocess- Overview natural and synthetic DBM processOverview natural and synthetic DBM process
- Main cost drivers synthetic DBM processMain cost drivers synthetic DBM process
- Overview of synthetic DBM producersOverview of synthetic DBM producers
Key areas in synthetic DBM Key areas in synthetic DBM processingprocessing - Energy consumptionEnergy consumption
- EnvironmentEnvironment
- Consistency and characteristics of synthetic Consistency and characteristics of synthetic DBMDBM
- CapacityCapacity
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Nedmag has increasedNedmag has increasedits capacity to 165 000 tits capacity to 165 000 t
Yearly MgO production 1994 - 2008
100
110
120
130
140
150
160
170
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
kT
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Cement demand will Cement demand will increaseincrease
by 5 % per year on average by 5 % per year on averageCement demand in billion MTCement demand in billion MT
(Source: Cembureau)(Source: Cembureau)
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
2000 2005 2010 2015 2020
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Steel demand will increaseSteel demand will increase by 4 % per year on average by 4 % per year on average
Steel demand in billion MTSteel demand in billion MT(Source: World Steel Association)(Source: World Steel Association)
0,5
1,0
1,5
2,0
2000 2005 2010 2015 2020
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1 Million T Synthetic DBM Capacity 1 Million T Synthetic DBM Capacity ClosuresClosures
CompanyCompany CountryCountry DateDate TechnologyTechnology MT paMT paSteetley Steetley UKUK 19911991 SeawaterSeawater 100 000100 000National RefractoriesNational RefractoriesUSAUSA 19941994 SeawaterSeawater 100 000100 000Sardamag Sardamag ItalyItaly 19941994 SeawaterSeawater 70 00070 000PenolesPenoles MexicoMexico 19941994 SeawaterSeawater 70 00070 000Shin NihonShin Nihon JapanJapan 19951995 SeawaterSeawater 100 000100 000BirlaBirla IndiaIndia 19981998 SeawaterSeawater 50 00050 000Asahi GlassAsahi Glass JapanJapan 19991999 SeawaterSeawater 30 00030 000Ube Industries *Ube Industries * JapanJapan 1990’s1990’s SeawaterSeawater 200 000200 000Martin Marietta *Martin Marietta * USAUSA 1990’s1990’s BrineBrine 50 00050 000CogemaCogema ItalyItaly 20032003 SeawaterSeawater 50 00050 000Harbison Walker Harbison Walker USAUSA 20032003 BrineBrine 100 000100 000JormagJormag JordanJordan 20052005 BrineBrine 40 00040 000Dead Sea PericlaseDead Sea Periclase IsraelIsrael 20052005 BrineBrine 40 00040 000
TOTALTOTAL 1 000 0001 000 000* still producing DBM at reduced capacity* still producing DBM at reduced capacity
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Future supply-demand for Future supply-demand for synthetic DBM not balanced? synthetic DBM not balanced?
Higher demand for cement and Higher demand for cement and steelsteel
Lower supply for synthetic DBMLower supply for synthetic DBM
Nedmag studying future capacity Nedmag studying future capacity expansionexpansion
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Link to movie(repackage movie in 3 minutes)
Shortcut to Nedmag Movie.lnk
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Thank Thank you!you!