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A Holistjc Approach to Cement Raw Materials Management 15 th Green Cementech 2019, Hyderabad, 30 & 31 May 2019 cobo GmbH Cornelis Bockemhl (c) 2019 Agenda A holistjc view at cement raw materials management Presentjng a new tool:

SLIDE 1

A Holistjc Approach to Cement Raw Materials Management

15th Green Cementech 2019, Hyderabad, 30 & 31 May 2019

SLIDE 2

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 2

Agenda

A holistjc view at cement raw materials management
Presentjng a new tool: AthosGEO Blend
Cost and benefjt – economic and ecologic
Steps and requirements

SLIDE 3

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 3

A Raw Materials Story

Raw material assessment for a new plant

(could also be an existjng plant)

– Primary component – Secondary component – Correctjves

Correctjve Correctjve

Unit A Unit B Unit C

Quarry Lifetime N years

SLIDE 4

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 4

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

SLIDE 5

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 5

A Raw Materials Story – contjnued

The market allows to ofger new cement type

– Raw material quality requirements will change Cement Cement Cement New Cement

Quarry Lifetime ?

SLIDE 6

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 6

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

Old Correctjve New Correctjve

Quarry Lifetime ?

SLIDE 7

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 7

A Raw Materials Story – contjnued

Emission regulatjons are changing

– Avoid areas with high S

r other in the quarry

High S

Quarry Lifetime

SLIDE 8

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 8

A Raw Materials Story – contjnued

And so on !!

Recurring Questjon: How exactly does all this afgect overall

peratjng CAPEX, OPEX and quarry lifetjme?

SLIDE 9

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 9

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

SLIDE 10

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 10

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"?

SLIDE 11

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 11

"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

pportunitjes

We need a tool that deals with proper blending

SLIDE 12

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 12

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)

SLIDE 13

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 13

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

SLIDE 14

15th Green Cementech 2019 - Cornelis Boc kemühl: AthosGEO Blend

Quarry block model with qualities and geological units Quarry block model with blocks to be mined (in red) Mined tons and qualities for both products Product specifications and quality constraints Correctives and other added materials

SLIDE 15

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 15

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

SLIDE 16

15th Green Cementech 2019 - Cornelis Boc kemühl: AthosGEO Blend

Quarry block model with marked start blocks Tons and qualities per mining period Quarry block model with taken blocks per mining period

SLIDE 17

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 17

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

SLIDE 18

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 18

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

SLIDE 19

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 19

Cost and Benefjt – Economic

Quarry lifetjme Cost per ton Find your Optjmum between maximum possible quarry lifetjme and overall cost per ton

SLIDE 20

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 20

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

SLIDE 21

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 21

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

SLIDE 22

15th Green Cementech 2019 - Cornelis Bockemühl: AthosGEO Blend 22

A Holistjc Approach to Cement Raw Materials Management

15th Green Cementech 2019, Hyderabad, 30 & 31 May 2019

Agenda

A Raw Materials Story

(could also be an existjng plant)

– Primary component – Secondary component – Correctjves

Unit A Unit B Unit C

Quarry Lifetime N years

A Raw Materials Story – contjnued

in the quarry

– Do not mine zones with

high MgO (cutofg)

High Mg

Quarry Lifetime

A Raw Materials Story – contjnued

– Raw material quality requirements will change Cement Cement Cement New Cement

Quarry Lifetime ?

A Raw Materials Story – contjnued

lower cost correctjve or an interestjng alternatjve raw material

– Mines need to adapt

productjon quality target

Quarry Lifetime ?

A Raw Materials Story – contjnued

– Avoid areas with high S

High S

Quarry Lifetime

A Raw Materials Story – contjnued

Recurring Questjon: How exactly does all this afgect overall

Dwindling Quarry Lifetjme

while in others we don't know

– the occurring problems and challenges and by – inadequate solutjons

Adequate solutjons are all about proper blending

Dealing with the Challenges

– Target is maximum discounted benefjt

– Highest benefjts will come fjrst

Questjon: What is "high grade cement raw material"?

"High Grade Cement Raw Material"

– Short answer: NO! – Long answer: It destroys your best blending

We need a tool that deals with proper blending

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

– Document and illustrate your quarries and results

with a powerful 3D visualizer (www.paraview.org)

A Cement Raw Materials Optjmizer

– correctjves, alternatjve raw materials etc.

– like: cement raw mix + mineralizer limestone

The sofuware tells you the potentjal maximum

Quarry block model with qualities and geological units Quarry block model with blocks to be mined (in red) Mined tons and qualities for both products Product specifications and quality constraints Correctives and other added materials

And a Quality Based Scheduler

– 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

Quarry block model with marked start blocks Tons and qualities per mining period Quarry block model with taken blocks per mining period

Cost and Benefjt - Economic

existjng deposits

maximum use of benefjcial alternatjve raw materials

and minor element limits

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

Cost and Benefjt – Economic

Quarry lifetjme Cost per ton Find your Optjmum between maximum possible quarry lifetjme and overall cost per ton

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

Steps and Requirements

– Understand the concept at depth

– No "silo optjmizatjon" of single units

– Know the optjons for facts based decisions

Thank you for your Interest

Please have a look also at the Partners

Contact htups://cobo.bockemuehl.ch cornelis@bockemuehl.ch

Global Cement Magazine

April 2019 issue, p 16ff