A Holistjc Approach to Cement Raw Materials Management 15 th Green Cementech 2019, Hyderabad, 30 & 31 May 2019 cobo GmbH Cornelis Bockemühl (c) 2019
Agenda ● A holistjc view at cement raw materials management ● Presentjng a new tool: AthosGEO Blend ● Cost and benefjt – economic and ecologic ● Steps and requirements 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 2
A Raw Materials Story ● Raw material assessment for a new plant (could also be an existjng plant) – Primary component – Secondary component – Correctjves Unit A Correctjve Correctjve Unit B Quarry Lifetime Unit C N years 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 3
A Raw Materials Story – contjnued ● Detail exploratjon fjnds zones of elevated Mg in the quarry – Do not mine zones with high MgO (cutofg) High Mg Quarry Lifetime 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 4
A Raw Materials Story – contjnued ● The market allows to ofger new cement type – Raw material quality requirements will change New Quarry Lifetime Cement Cement Cement Cement ? 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 5
A Raw Materials Story – contjnued ● Procurement fjnds an opportunity for some lower cost correctjve or an interestjng alternatjve raw material – Mines need to adapt productjon quality target New Old Correctjve Correctjve Quarry Lifetime ? 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 6
A Raw Materials Story – contjnued ● Emission regulatjons are changing – Avoid areas with high S or other in the quarry Quarry Lifetime High S 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 7
A Raw Materials Story – contjnued ● And so on !! Recurring Questjon: How exactly does all this afgect overall operatjng CAPEX, OPEX and quarry lifetjme? 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 8
Dwindling Quarry Lifetjme ● In many cases lifetjme will dwindle, while in others we don't know ● Quarry lifetjme will be afgected by both – the occurring problems and challenges and by – inadequate solutjons Adequate solutjons are all about proper blending 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 9
Dealing with the Challenges ● Classical ways to optjmize mining operatjons – Target is maximum discounted benefjt ● Typical strategy is highest grades fjrst – Highest benefjts will come fjrst Questjon: What is "high grade cement raw material"? 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 10
"High Grade Cement Raw Material" ● There is no such thing! ● Should we mine high grade limestone fjrst instead? – Short answer: NO! – Long answer: It destroys your best blending opportunitjes We need a tool that deals with proper blending 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 11
AthosGEO Blend ● The required tool is AthosGEO Blend – Optjmizer – calculate the maximum potentjal raw mix, including all materials from the quarry to the kiln feed, and fjnd the optjmum in terms of cost and quarry lifetjme – Scheduler – generate a mining schedule that maintains the quality targets ● Additjonal value – Document and illustrate your quarries and results with a powerful 3D visualizer (www.paraview.org) 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 12
A Cement Raw Materials Optjmizer ● You enter the block model(s) of your quarry(ies) ● You enter your additjonal materials – correctjves, alternatjve raw materials etc. ● You enter your products and requirements – like: cement raw mix + mineralizer limestone The sofuware tells you the potentjal maximum 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 13
Quarry block model Correctives and other with qualities and added materials geological units Product specifications and quality constraints Quarry block model with blocks to be mined (in red) Mined tons and qualities 15th Green Cementech 2019 - Cornelis Boc for both products kemühl: AthosGEO Blend
And a Quality Based Scheduler ● Once you know your raw materials potentjal – You need to know where you want to start mining – The sofuware will check if it's possible and contjnue And for every period all requirements will be met 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 15
Quarry block model with marked start blocks Tons and qualities per mining period Quarry block model with taken blocks per mining period 15th Green Cementech 2019 - Cornelis Boc kemühl: AthosGEO Blend
Cost and Benefjt - Economic ● Maximum lifetjme with minimum waste for existjng deposits ● Minimum use of costly correctjves and maximum use of benefjcial alternatjve raw materials ● Avoid mitjgatjon cost for exceeding emission and minor element limits 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 17
Cost and Benefjt – Economic Improved quality control in the mines is not without cost... ...but it is stjll less than dealing with quality issues later 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 18
Cost and Benefjt – Economic Find your Optjmum between Cost per ton maximum possible quarry lifetjme and overall cost per ton Quarry lifetjme 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 19
Cost and Benefjt – Ecological No cement productjon without use of non- renewable natural resources It's our duty to future generatjons to use them as economically as possible 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 20
Steps and Requirements ● Train the experts – Understand the concept at depth ● Cooperatjve mind set in plants and mines – No "silo optjmizatjon" of single units ● Sofuware tool to support the approach – Know the optjons for facts based decisions 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 21
Thank you for your Interest Global Cement Magazine Contact April 2019 issue, p 16ff htups://cobo.bockemuehl.ch cornelis@bockemuehl.ch Please have a look also at the Partners 15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 22
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