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AT VEENDAM, in north-east
Netherlands, Nedmag
Industries Mining &
Manufacturing BV owns a
magnesia operation
somewhat unique amongst
producers. Nedmag sources
its magnesia by solution
mining magnesium chloride
deposits (bischofite/carnallite)
of the Zechstein basin some
2km below the surface.
From this rich source,
which yields about 500,000
tpa of raw magnesium-rich
salts, Nedmag produces a
suite of products including
A Dutch Aerial view of part of the
Veendam complex
showing the precipitation
and washing tanks

solution for
dead burned magnesia
(DBM), caustic calcined
magnesia (CCM),
magnesium chloride,
magnesium hydroxide, and
calcium chloride. However,

magnesia
Nedmag has come a long
way from its start-up as a
DBM-only producer.

Nedmag annual production

(tonnes)
DBM 153,000 Nedmags response to market changes
CCM 6,000 bulk, 1,000 bags has ensured its survival as a leading producer
40,000 flakes; 41,000
of DBM while diversifying its product portfolio.
MgCl2
liquid (100% basis)

Mg(OH)2 4,000 (100% basis)
CaCl2 25,000 prills, 22,000
liquid (100% basis)
History
During the course of
exploratory drilling for gas in
the Groningen area, north of
the Netherlands, Royal
Dutch/Shell encountered a
layer of the magnesium
chloride minerals, bischofite
and carnallite. This
unexpected discovery of a
unique bischofite deposit
provided the incentive for a
new venture. In 1979, Shell
formed a joint venture
between subsidiary Billiton
Nederland BV and NV
Noordelijke Ontwikkelings
Maatschappij (NOM), a
Dutch Investment Bank,
called Magnesia International
(Magin), to produce dead
burned magnesia, which
started in 1981. An associate
company, Noordelijke
62
Zoutwinning BV (NOZO)
was responsible for the
mining of the magnesium
salts (see panel).
In 1987, Magin and
NOZO merged into Billiton
Refractories BV, wholly owned
by Billiton Nederland BV, and
ultimately owned by Shell
Petroleum BV.
In 1994, the company
passed into the hands of a
new group of shareholders,
and was renamed Nedmag
Industries Mining and
Manufacturing BV, in which
Nedmag stands for
Nederlandse Magnesia. The
ownership is NOM, 47%,
Lhoist Group, 47%,
management, 6%.
However, since its start-up
in 1981, market trends,
especially with regard to
DBM use in refractories,
influenced Nedmags
business plans and ultimately
necessitated a major strategy
review in the mid-1990s.
Strategic review
Initially, Nedmags prime
focus was solely on DBM
production, but by 1993 the
company realised the need
to implement a major
change in strategy. Nedmag
refocused its DBM
production and marketing,
and diversified.
In the late 1980s to early
1990s, Nedmags DBM
(nedMag99) was mostly
aimed at the magnesia-
carbon refractory brick
market for the iron and steel
industry. However, towards
the end of that period,
Nedmag started to serve
the magnesia-spinel
refractory brick market. This
market had largely arisen
from the need to replace
chromite-bearing bricks in
cement kilns (owing to their
post-use hazard to the
environment with Cr6+) with
an alternative refractory
product, ie. mag-spinel.
At the same time, there was
a change in emphasis from
steelmakers to produce
alternative low carbon quality
steel (thus less mag-carbon
brick use), and increased
competition in magnesia
supply for mag-carbon bricks
from lower cost sources of
DBM, and increasingly fused
magnesia (as a DBM
substitute) from China.
In Nedmags view, there
appeared only one option to
take, to tackle fixed costs
per metric tonne of DBM. To
achieve this, Nedmag took
steps to increase production
by utilisation of extra
capacity, a company-wide
strategic quality plan, and a
new marketing approach.
Nedmag felt the need to
change its whole concept
from one of being a niche
market layer, to a leading
producer. To this end the
company set out to explore
the potential of long term
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relationships with the main chloride activities of Kappe

strategic customers and
identify new geographic
regions not previously
considered for sales.
It was already clear that
DBM production capacity
and consumption was in
decline. During 1992, total
DBM world production
capacity was some 1.8m.
tpa. Since that time, there
have been a series of high
profile exits by players from
the DBM supply market, and
by 2004 world production
capacity had dropped by
66% to around 600,000 tpa.
Nedmags sales of DBM to
mag-spinel bricks have
increased from 60,000
tonnes in 1993, to almost
120,000 tonnes in 2004.
While sales to mag-carbon
peaked in 1999 with about
50,000 tonnes, they have
dropped to less than 40,000
tonnes in 2004.
In addition to refocusing its
DBM marketing, Nedmag
sought to diversify its product
portfolio on the basis of its
raw material source, ie.
magnesium chloride, to
produce magnesium chloride
and calcium chloride grades.
In 1993, Nedmag further
developed its MgCl2
production. As of 1996 they
successfully managed to
convince the market to take
MgCl2 flakes besides liquid.
In 2001, Nedmag secured
its CaCl2 production facilities
through the acquisition of
the on-site calcium
November 2004
Intermediair and Kareva
BV, thus complementing
and consolidating Nedmags
salt business.
Prior to 1993, 100% of
the companys turnover
represented DBM production,
but today that figure has
reduced to 75% for DBM,
with the remainder being
MgCl2, 11%, CaCl2, 10%,
CCM, 3%, Mg(OH)2, 1%.
Markets
Nedmags DBM grade
(nedMag 99) is mostly
consumed by producers of
magnesia-spinel refractories
(about 80% of output) for
mostly cement kiln
applications, while the
remainder is used in other
magnesia-based steel refrac-
tories such as mag-carbon,
mag-dolomite, and
magnesite bricks.
CCM (nedMag 99) serves
a range of markets including,
spinel manufacture, printing
inks, cements, fertilisers, feed
additives, water treatment
products, polymers, pulp and
paper, and sugar.
Markets for CaCl2
(nedMag Ca) include de-
icing, dust suppression, oil
and gas exploration, and
other industrial applications.
Some CaCI2 is shipped to
North America for de-icing
and de-dusting applications.
Nedmags MgCl2 flakes
are exported as far afield
as New Zealand. Market
applications for MgCl2
Calcium chloride product in big Kisuma started a
bags awaits shipment from 20m. expansion
Veendam. Some goes as far North to the plant that
America for the de-icing market.
Above: Production of MgCl2 flake. Markets include de-icing, dust
suppression, Sorel cement flooring, grinding & polishing stones,
and animal feed.
Below: Looking towards the adjacent operation of Kisuma Chemicals
from Nedmags plant. Kisuma is the European affiliate of Japanese
flame retardant leader Kyowa Chemical Industry Co. Ltd. It receives
MgCl2 flake feedstock from Nedmag.
(nedMag C) include de-icing, its initial 10,000 tpa capacity
dust suppression, Sorel by 2007.
cement flooring, grinding & Mg(OH)2 (nedMag H) is
polishing stones, animal used in industrial
feed, and providing applications such as the
feedstock for the production of polymers,
neighbouring Mg(OH)2 paper, rubber, plastics,
flame retardant and printing inks, fertilisers and
hydrotalcite production as an alkali in the neutrali-
facility of Kisuma sation of acid waste streams.
Chemicals BV. The attached table shows
Set up in 1999 after Nedmag's production
securing a deal estimates for 2007, showing
with Nedmag for increased volumes for DBM,
MgCl2 feedstock the core product, but also
supply, Kisuma significant rises in figures for
Chemicals is the CaCl2 and MgCl2.
European affiliate
Nedmag projected
of Japanese flame
production volumes
retardant leader
2007 (tonnes)
Kyowa Chemical
Industry Co. Ltd, DBM/CCM 175,000tpa
and its plant is
45,000 tpa flakes;
adjacent to the MgCl2 45,000 tpa liquid
Nedmag operation. (100% basis)
In February 2004,
Mg(OH)2 6,000 tpa (100%)
CaCl2 50,000 tpa prills,
30,000 tpa (100%)
intends to double
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Solution mining Nedmags

Nedmag solution mines carnallite and bischofite salt from the
Zechstein salt deposit near Veendam with a unique mining
method. From two mining sites, a total of 12 wells were drilled
between 1972 and 1991 at a depth between 1,400 and 1,800
metres, which have an average production capacity of about
25m3/hour of brine per well.
process route
Solution mining
Magnesium chloride salts are extracted from a depth of
approximately 1,500 metres. By a modern solution mining
technique, these salts are dissolved by introducing water
under high pressure, after which the formed concentrated
brine (>30% magnesium chloride) is pressed upwards. This
crude brine is sold as nedMag-SQ (Standard quality)

Some of the 12 wellheads at the Veendam operation. Magnesium
chloride salts are extracted from a depth of approximately 1,500 metres.
Inset: Theo Eerens, head of Nedmag operations (left) with Paul de Korte,
VP marketing and sales
The mining method applies two unique features of the magnesium
salt: their tendency to creep (deform under small loads), and their
tendency to dissolve preferentially over sodium chloride. Injection
of water in the cavern mixes up the low density (1kg/l) with the
high-density brine (1.3-1.37kg/l) to cause high mixing by turbulent
buoyancy effects. The mixed flow does not (or almost not) dissolve
sodium chloride, by which the natural sodium chloride (halite)
layers force the dissolution to proceed in a sidewards direction
along the bedded magnesium salts.
Purification
For some applications, extra purification of the magnesium
chloride brine is required. By means of an active coal filter
undissolved iron is removed, resulting in nedMag C - FQ
(filtered quality).
Further purification is achieved by oxidation of the dissolved
iron into Fe(III) precipitate followed by membrane filtration
and an additional active coal filtration, giving nedMag C -
PQ.
Flaking
The magnesium chloride can be provided in a solid form as
well. For this purpose the brine is heated to get a saturated
solution of 47% magnesium chloride. This hot concentrated
liquid is then transported to a water cooled rotating drum,
where solid magnesium chloride flakes are formed:
nedMag C - flakes.

The unique creep properties, and the relatively low cavern
pressures (of an average of 10 MPa (100 bars) below the far field
rock stresses) make the salts flow towards the well, hence allowing
them to be dissolved once more for production purposes.
Since the magnesium salts are squeezed into the caverns like
toothpaste, this method is called squeeze mining. The brine from
this salt is very pure (less than 1% by weight of impurities like
sulphates, sodium of potassium), as a result of the extreme
predominant solubility of bischofite. The brine density at room
temperature is some 1.33 kg/l.
Four wells currently produce brine saturated with the salt bischofite,
rendering a very high
Typical Veendam brine properties
quality brine, with less
bischofitic brine carnallitic brine than 1% by weight of
non-magnesium chloride
MgCl2% 32 23
salts. These brines are
Boron removal
Crude magnesium chloride brine for MgO production is
treated in an ion exchanger for boron removal. The boron
selective resin is regenerated with hydrochloric acid.
Subsequently the sulphate in the brine is reduced by using
calcium chloride brine, the gypsum precipitate CaSO4
2H2O formed is thickened, dewatered on a vacuum
beltfilter and disposed of in the MgCl2 caverns from where
the raw brine originated. The overflow from the thickener is
the purified brine ready for use in the magnesium hydroxide
precipitation stage. Both boron and sulphate must be
reduced in order to improve the chemical purity of the and
refractoriness of the magnesium hydroxide and sintered
magnesium oxide respectively.

KCl% 0.3 4.5 used for the production of
DBM, CCM, MgCl2,
NaCl% 0.4 1.5 Mg(OH)2 and CaCl2 (all
MgSO4% 0.3 1.5 produced at the plant Dolime slaking
4km away, brine is The raw material, solid dolime (CaO.MgO) has to be slaked
H2O% 67 68 pumped via a pipeline, before it can be used in the process. Slaked dolime is used for the
MgCl2 flake is produced next process step - magnesium hydroxide precipitation . Slaking
density kg/l 1.31 1.27 involves an exothermic hydration reaction of dolime with water,
at the well head site).

64 November 2004

whereby predominantly the calcium oxide component is
transformed in its hydroxide. The dolime used for the process is
provided by Groupe Lhoist in Belgium. First the precursor
chemically pure dolomite (CaCO3.MgCO3) is produced by
selective mining in an open quarry in Marche les Dames,
Belgium. This dolomite is subsequently transported to Hermalle,
Belgium, where it is calcined at specific temperatures to control
the reactivity of the dolime. Nedmag consumes in the order of
3,500 tpw dolime from Lhoist.
Precipitation
The slaked dolime is brought in contact with desulphated
magnesium chloride brine. Whereby calcium hydroxide
reacts with magnesium chloride to form a magnesium
hydroxide precipitate and calcium chloride. The magnesium
oxide originating from the slaked dolime will partly hydrate
but is still present in the magnesium hydroxide precipitate.
The spent calcium chloride brine is reused in the brine
purification process.
CaCl2 concentration
Calcium chloride brine 16% is stored in a 5,000m3 tank as
feedstock for the plant and for bulk loading purposes.
Sulphate present in the brine must be removed to prevent
scale formation in the process downstream, by introducing
a barium chloride solution is the sulfate precipitates as solid
barium sulfate. Barium sulphate solids are removed in a
settler and removed as a high solids sludge. The sludge is
used as drilling agent in the oil and gas industry. In a
multiple effect plate evaporator the brine is further concen-
trated to 40% and 55% CaCl2. The 40% is stored in basin
and the 55% is the feed for the next stage: prilling.
CaCl2 prilling
For prills production, hot air is needed, this air is generated
in a natural gas burner system where cold atmospheric air
is pressed along the burners. The airheater produces air
with a temperature of 480C, which after passing the
prilling tower is dedusted in a cyclone and a wet scrubbing
system. In a fluid bed granulation tower 55% solution is
further concentrated with hot air to a approx. 3 mm
granulated particle with 96% CaCl2. These so called hot
prills are screened, cooled and stored in large bins. From
these bins bulk loading is available and is also from where
the big bags and 25kg package lines are fed.
Washing
The slurry, containing magnesium hydroxide solids and
solved calcium chloride, is washed countercurrently to
remove all chlorides. During this process a flocculant is
added to improve the settling and compaction behaviour of
the magnesium hydroxide.
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Vacuum drum filter
In three vacuum rotary drum filters, the magnesium suspension is
dewatered to form a filter cake with approximately 54% solids.
This substance is transported to the next operation stages, the
calciners, and the stabilisation process for the production of
nedMag H suspension.
Calcining
The magnesium hydroxide filter cake is fed into two multistage
Herreshoff furnaces, where the material is further dried and
calcined to form caustic magnesium oxide. This calcination
process is carried out at controlled temperatures (up to
1,100C), using natural gas/air burners. The produced caustic
powder is further transported to the briquetting section for
densification or supplied as nedMag 99 Caustic Powder.
Briquetting
In two stages the caustic magnesium oxide powder is
compacted into almond shaped briquettes. Subsequently these
so called green briquettes are sieved and fed into the shaft
kilns for sintering or supplied as nedMag 99 Caustic Briquettes.
Sintering
The green briquettes are sintered (dead burned) in a shaft
kiln with an oval shaped cross section. The residence time
in the shaft kiln, is controlled by a drag bar, a moving beam
on a table, that removes the product from the kiln. By
means of natural gas / air burners a temperature of up to
2,200C is reached, to produce dense high purity dead
burned magnesia: nedMag 99 Briquettes.
Grinding & milling
nedMag 99 -DBM Briquettes are used as feedstock in the
grinding and milling process. Firstly the briquettes are crushed
below a size of 6mm. This product can be sieved in one or two
steps to the various required fractions or fed into a ball mill
where it can be sized down to various mesh sizes. The different
sizes are packed either in 1,000kg bigbags or in 25kg paper
bags both with polyethylene-inliners if required.
Maintenance and repair of a shaft kiln at Nedmag. Calcined green
magnesia briquettes are dead burned in shaft kilns at 2,200C to
produce high purity DBM
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