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1
Ethiopia
ASEC Company for Geology & Mining
“ASCOM”
Contents
•Importance of raw materials in Cement
•ASCOM Profile
•ASCOM Experience in Raw Material Evaluation and
Quarry Operation (Case study)
•ASCOM in Ethiopia
Raw Material in CementRaw Material in Cement
Historical background
•The term cement is commonly used to refer to powdered materials which develop strong adhesive
qualities when combined with water. These materials are more properly known as hydraulic cements.
Gypsum plaster, common lime, hydraulic limes, natural pozzolana, and Portland cements are the more
common hydraulic cements, with Portland cement being the most important in construction.
•Cement was first invented by the Egyptians. Cement was later reinvented by the Greeks and the
Babylonians who made their mortar out of lime. Later, the Romans produced cement from pozzolana, an
ash found in all of the volcanic areas of Italy, by mixing the ash with lime.
•Cement is a fine grayish powder which, when mixed with water, forms a thick paste. When this paste is
mixed with sand and gravel and allowed to dry it is called concrete.
•The cement industry in Egypt, one of the oldest industries, and works in this sector about 20 plants
produce 57 million tons of cement annually.
Introduction
General
• To imagine how much raw materials the Cement industry
removes from the earth crust in one year , one should
recognize that
• Total number of cement plants : 1820
• Cement manufacturing countries : 135
• In 2004 The world production of OPC : 1700 MTA
• The amount of dry raw materials : 3030 MTA
• The amount of natural raw materials : 3157 MTA
• The amount of natural raw materials with 4% Gypsum addition:3283 MTA
• Produce about 1661 MTA of Carbon dioxide
Raw Materials are the bases of all business in the cement industry.
For clinker (Cement) production a certain quality of raw materials is
required.
Ordinary Portland Cement ( OPC ) , by far the most commonly
used type of cement consists mainly of the following ingredients
expressed as oxides : -
Raw Material Importance
Introduction
Ordinary Portland Cement ( OPC ) , by far the most commonly
used type of cement consists mainly of the following ingredients
expressed as oxides : -
Raw Material Importance
Introduction
Calcium oxide 64 % CaO “ Calcium “ , C
Silicon Oxide 22 % SiO2 “ Silica “ , S
Aluminum oxide 6 % Al2O3 “ Alumina” , A
Iron Oxide 3 % Fe2O3 “ Iron ” , F
Na2O , K2O “ Alkali “
SO3 “ Sulphur”
MgO “Magnesium”
TiO2 “ Titanium”
Cl “ Chloride “
Major
Oxides
Minor
Oxides
Raw Materials The Main Components
Check-List for Potential Cement Raw Material
I. Calcareous Materials: (Limestone)
Carbonate Titration: > 80 %
As CaCO3
MgO < 4.0 %
SO3 < 1.0 %
P2O5 < 1.0 %
Cl < 0.1 %
II- Argillaceous Materials : (Clay – Marl) Total Alkalis as Depending on
Na2O Equivalent Cement Type
Al2O3 > 10.0%
SO3 < 1.0 %
Cl < 0.1 %
Raw Materials The Auxiliary Components
CORRECTIVE MATERIALSCORRECTIVE MATERIALS Materials rich in SiO2 (Sand), or Al2O3 (Bauxite) or Fe2O3 (Iron Ore) used to satisfy the
deficit in the raw mix.
ADDITIVEADDITIVE MATERIALSMATERIALS
Added to the clinker to obtain special effects
Examples:
Gypsum added to regulate the initial setting.
Fluorspar added to improve the burnability.
Raw Materials The Deleterious Constituents
Are Defined as components which:
- Affect the quality or marketability of cement.
- Increase Production costs through difficulties in Preparation and
Processing in the kiln.
• Alkalis
• MgO
• SO3
- Cl
- P2O5
- Fluorine (F):
- Mn2O3
- Cr2O3
- TiO2
Cement in Egypt
The prominent growth of cement industry in Egypt is mainly due to the
abundance of cement raw materials.
0.10 0.36
22.60
36.30
57.00
0.00
10.00
20.00
30.00
40.00
50.00
60.00
1900 1929 2004 2006 2013
MT
A
Year
Cement Plants in EgyptCement Plants in Egypt
Cement in Egypt Cement Plants in EgyptCement Plants in Egypt
LocationLocation ofof cementcement plantsplants inin EgyptEgypt
ASCOM ProfileASCOM Profile
History
1975
Geology department of ASEC Group is born
Over 25 years, the department developed
excellent reputation in
Geological investigation
Mining planning
Quarries technical assistance
Servicing all the cement plants in Egypt
1998
Privatization of cement
plants in Egypt
1999
ASEC Company for
Mining “ASCOM” is born
2004
ASEC Group purchased by
Citadel Capital
2007
ASCOM separated from ASEC
& follow Citadel Capital directly
15
Strategy and Vision
ASCOM has historically been extremely successful in expanding its quarry management operations all while focusing mainly on the cement industry
across the MENA region
Following Citadel Capital’s 2004 acquisition of ASEC, and its spin-off from ASEC in 2007, ASCOM has redefined its strategy to focus on
complementing its expertise in Quarry Management with studied expansions into new business lines that management have deemed both profitable
and necessary to meet today's market demands
In year 2015, ASCOM
– continue to increase the Company’s Ground Calcium Carbonate production capacity to serve high margin export markets such as India and South
Africa, whilst capitalising on its first-mover advantage in the production of glass and rock wool insulation in Egypt
– develop its precious metals mining business in Ethiopia
– grow mining operations focusing on raw materials related to the construction industry such as aggregates and armored blocks
– continue expanding into mining of other raw materials such as gypsum, kaolin, phosphate and silica sand
Vision
Re-structure the group on a functional basis (ongoing)
The vision is to continue to expand in the following products and countries:
–Quarry Management
–Aggregates
–Calcium Carbonate
–Glass Wool and Rock Wool
–Precious metals (Gold)
–Phosphates
׃ Egypt, Algeria, Ethiopia, KSA, Sudan
׃ Egypt, Algeria
׃ Egypt
׃ Egypt
׃ Ethiopia
׃ Egypt
16
ASCOM Operations and Activities
Calcium carbonate reserves in Egypt
rank as the 2nd best worldwide in
terms of grade and brightness after
those of Carara, Italy
ASCOM used its mining expertise
and invested in the manufacturing of
Ground Calcium Carbonate through
a USD 20 million Greenfield factory
in El Minya - Upper Egypt
Expansion work costing USD 7.3
million was completed in June 2013
which will increase the current milled
capacity from 120,000 tons p.a. to
240,000 tons p.a. A further 240,000
tons p.a. of milled capacity will be
added over the next two years.
Similarly, ASCOM has employed its
technical know-how to invest in the
manufacturing of rock wool and
glass wool to draw on the high grade
of available raw materials in Egypt
through the construction of a
Greenfield, USD 65 million
manufacturing plant with a capacity
of 50,000 tons per annum of glass
wool and rock wool.
Manufacturing Mining Quarry Management and Services
Research and Geology
Full geological investigation programs
Geophysical studies
Mining planning
Quarries Management
Total Quarry Management up to supply of
raw materials such as limestone, clay,
silica sand and gypsum for a number of
clients mainly within the cement industry.
ASCOM’s market share of cement raw
material supply in Egypt is over 40% with
over 40 million tons supplied in 2012
Technical Assistance
Technical Office
Survey works
Road design and construction
Blasting services
Full blasting operations
Measurement of blasting vibrations
Explosives magazines
ASCOM has secured a number of
concessions in Ethiopia and Sudan
for the exploration of precious and
base metals such as gold, silver and
copper with a total land package of
over 4,400 km2.A gold discovery has
been made at the Asosa concession
in Western Ethiopia through
ASCOM’s subsidiary ASCOM
Precious Metals (APM)
ASCOM has broadened its
operational scope to cover mining of
building materials, to cater for this
rapidly growing segment
Mining of various raw materials such
as aggregates (2.8 mtpa), armoured
blocks, gypsum (300 ktpa), gravel
(120 ktpa), silica sand (250 ktpa) and
kaolin
Concessions in Egypt for silica sand,
gypsum, kaolin and aggregates
Concessions in Algeria for armoured
blocks and aggregates
ASCOM’s operations can be grouped under the following 3 business lines:
ASCOM Projects...
Project
Type S. Name and Description of the Project Client
Qu
arr
y O
pen
ing
an
d
Op
era
tio
ns
1 Limestone & clay quarries opening and complete quarry operations ( drilling,
blasting, loading & transport) Sinai Cement Company
2 Complete Quarry operations for limestone and clay quarries Helwan Cement Co. (Italcementi group)
3 Limestone & Clayey sand quarries opening and complete quarry operations
Misr Cement Company (Qena)
4 Overburden Removal
5 Complete quarry operations of limestone quarry Tourah Cement Company
6 Complete Quarry operations of clay Quarry
7 a-Limestone quarry opening and complete quarry operations
b-Supply of Kaolin, white sand and pure gypsum Sinai White Cement
8 Limestone quarry opening and complete quarry operations Misr Beni Suef Cement
9 Extraction and Supply of Clays
Ameryah Cement Co. (CIMPOR) 10 Feeding of external limestone and all raw materials, additives and correctives
11 Complete limestone quarry operations. Feeding of kaolin, gypsum & white sand El-Minya White Cement (Italicement)
12 Limestone and clay quarries opening and complete quarry operations Medcom Aswan for Cement
13 Limestone Quarry opening and complete quarry operations. Feeding of all raw
materials Royal El Minia White Cement Co.
14 Limestone Quarry opening and complete quarry operation South Valley Cement Co.
ASCOM Projects...
Project
Type S. Name and Description of the Project Client
Qu
arr
y O
pen
ing
an
d
Op
era
tio
ns
15 Limestone Quarry operation Suez Cement Co.
16 Gypsum Quarry Opening and Operation Zahrt Sinai – Gypsum
17 Limestone Quarry opening Tianjin Cement Design and Research
Institute Co. LTD
18 Limestone Quarry opening and complete quarry operations Al Shamal Cement Co. (Sudan)
19 Limestone and Clay quarries opening Al-Takamol Cement Co. (Sudan)
20 Quarry Operation (Phosphate) Al Nasr For Mining
21 Limestone and clay quarries opening and operation Al Nahda Cement Co.
22 Limestone quarry opening and operation Building Materials Industrials Co.
23 Limestone & Clay quarries opening and operation Arab national cement
24 Drilling for Blasting Arab Contractors
25 Clay quarry operation
Helwan Cement 26 Corrective Clay supply
27 Drilling Blasting Tourah Cement Company
28 Gypsum Extraction & Supply Knauf Ltd Co.
29 Limestone quarry opening TCDRI- GEO, Arish Cement
ASCOM Projects...
Project
Type S. Name and Description of the Project Client
Co
mp
lete
Geo
log
ical
Inv
esti
gati
on
1 Core drilling & chemical analysis of gypsum Arabian cement company
A C C ( KSA)
2 Complete geological investigation Al Wadi cement.
3 Complete geological investigation for clay in Wadi EL natron area Alex-cement ( Egypt)
4 Complete geological investigation for limestone in EL Hammam area Alex-cement ( Egypt)
5 Complete geological investigation Royal for white cement
6 Complete geological investigation Nahda cement ( Egypt)
7 Complete geological investigation Arab national cement
8 Core drilling of limestone (Wadi El Nile Cement) RHI (Egypt)
9 Complete geological investigation for dolomite Saint Gobain (Egypt)
10 Geological investigation AL deyar cement (Yemen)
11 Geological investigation Mada Gypsum (KSA)
ASCOM Projects...
Project
Type S. Name and Description of the Project Client
Co
mp
lete
Geo
log
ical
Inv
esti
ga
tio
n
12 Geological investigation National cement company
13 Complete geological investigation South valley cement
14 Complete geological investigation EL Safwa ( KSA)
15 Complete geological investigation EL jouf cement ( KSA)
16 Complete geological investigation Medcom Aswan ( Egypt)
17 Complete geological investigation Hajr cement co. ( KSA)
18 Complete geological investigation Zahrat Sinai for gypsum
19 Complete geological investigation Misr for cement (Qena)
20 Complete geological investigation of marble (Jabal labounah) Arabian cement company
ACC ( KSA)
21 Complete geological investigation of marble (Jabal Shahbiaa) Arabian cement company
ACC ( KSA)
22 Complete geological investigation High dam authority
ASCOM Projects...
Project
Type S. Name and Description of the Project Client
Co
mp
lete
Geo
log
ical
Inv
esti
gati
on
23 Complete geological investigation Lebdah (Libya)
24 Complete geological investigation G-RD cement plant-Iraq
25 Complete geological investigation whit sand EL Raghy for trade and industrial (Egypt)
26 Complete geological investigation Asec- Algeria
27 Complete geological investigation Asec- Syria
28 Complete geological investigation EL Takamaul (Sudan)
29 KSA –Prophet Holy Mosque Ben Laden- El Mansour
30 METZ- Holding Metz
ASCOM Projects...
Project
Type S. Name and Description of the Project Client
Su
pp
ly P
roje
cts
1 Supply of Gravel Several Clients
2 Supply of Glass Sand Several Clients
3 Supply of Limestone Al Dakahlia Sugar
4 Landfill Preparation Onyx Alexandria
5 Supply of gypsum ,iron oxide and sand Sinai Cement Company
6 Silica Sand Supply Saint Gobain for Glass
7 Silica Sand Supply Sphinx for Glass
8 Gypsum Supply Pan Arab for Building Materials
ASCOM Experience in Raw Material ASCOM Experience in Raw Material
Evaluation and Quarry OperationEvaluation and Quarry Operation
24
Preliminary Geological InvestigationPreliminary Geological Investigation
Raw Material Evaluation and Quarry
Operation
Contents
Geographical situation
Transportation Infrastructure
Potential Plant Site
Climate
Morphology Of The Deposit
Quarry Possibility
Environmental Conditions
Geological Situation
Raw Material Quality
Dumping area
Plant Site
To Qift- Qussier Road
Plant Site & Quarries Location
Limestone quarry
3 km NE plant site
Clayey Sand quarry
2 km NW plant site
Preliminary Geological Investigation
Objective :Location of Suitable Deposit With Reasonable Degree of
Prediction Reliability
Scope of Work:
Defining the Deposit in Topographic Maps
Samples Collection by Trenching or Core Drilling
Complete Chemical Analysis & Physical Tests
Preparation of Preliminary Raw Mix Design
Elaboration of Preliminary Geological Report
Drilling Grid
EXP1
EXP2
EXP3
EXP5
EXP6
806100 806200 806300 806400 806500 806600 806700 806800 806900 807000 807100 807200 807300 807400
806100 806200 806300 806400 806500 806600 806700 806800 806900 807000 807100 807200 807300 807400
372000
372100
372200
372300
372400
372500
372600
372700
372800
372900
372000
372100
372200
372300
372400
372500
372600
372700
372800
372900
OVERALL GEOLOGICAL INVESTIGATION
SAND DEPOSIT (B)
MISR CEMENT COMPANY (QENA)
0 500 1000
FIGURE (4)
Core Drilling Rig
GEOLGRAPHICAL SITUATION OF THE DEPOSITS
The morphology of the area under the investigation will be described in
order to show a real picture about the followings:
Transportation Infrastructure.
Potential plant site.
Climate
Morphology of the deposit
Quarry possibility
Environment.
31
Overall Geological Investigation
Raw Material Evaluation and Quarry
Operation
Drilling
Core Drilling
Auger Drilling
Rotary Drilling
Percussion Drilling
Geological Maps and Cross Section
Reserve Calculations
Overburden
Technological Testing (Crushability , Grindability , Burnability ,
Volatility )
Objective :Clear Characterization of Raw Material
Deposits in Quality & Quantity
Scope of Work:
Preparation of Contour Maps
Core Drilling on Regular Grid
Complete Chemical Analysis & Physical Tests
CADE Application
Preparation of Technological Sample
Technological Testing (Crushability , Grindability ,
Burnability , Volatility )
Raw Mix Preparation
Grade Reserve Estimation
Elaboration of Overall Geological Report
In the overall investigations of raw materials, the quality and the quantity of
1to 3 deposits are appraised. The following work has to be carried out in
order to obtain accurate information about the deposits:
Drilling:
1000 to 2000m of core drilling for the main deposit,
500 to 1000m for the secondary component
Purposes: description of the lithology, sedimentology, moisture content, porosity, density
compressive strength, etc.
•Chemical analyses of 13 constituents
LOI, SiO2, Al2O3,Fe2O3, CaO, MgO, SO3, K2O, Na2O, TiO2,P2O5, Mn2O3, Cl.
Geological mapping and cross-sections: scale 1:1000 to 1:2000
Purposes: distribution of the lithology/ formations, structures.
Calculation of reserves.
Geophysics, if necessary.
Raw mix design.
Preliminary concept of quarrying.
Bulk samples for technological tests.
Drilling Grid
Drilling
Core Drilling
Auger Drilling
Rotary Drilling
Percussion Drilling
Diamond core drill
These involve driving a fast rotating annular bit through the rock
and so obtaining a solid undisturbed sample.
The bits are either diamond impregnated or surface set.
Occasionally, other materials such as tungsten may be used.
In terms of sample weight or lineal metering this is at least three
times as expensive as any other drilling methods at similar depth.
Core Drilling
Core Drilling (Continued)
Circulating Fluid
Core Barrel
Core Recovery
Core Size
Core Storage
Core Sampling
Other Types of Drilling
•Auger drill The principle component is a slowly rotating rod. The material from the hole is forced
upward by the wedging action of the bit tips and by a spiral ledge fixed to the exterior of
the rods.
These rigs are unsuitable in unconsolidated alluvial (pebble, sand, clay) or rocks.
•Rotary drill This method uses a slowly rotating rod string on the end of which a bit scrapes by point
pressure. The flushing of cuttings may be by air, water or mud. The cost remain valuable
compared to the core drilling (30 to 60% lower).
•Percussion drill These are based on having a slowly rotating chisel hitting the rock. The method of
application of force to chisel allows a classification as follows:
Uphole hammer drill
Downhole hammer drill
Conclusion:
All Chemical Variations and Physical
Properties Are Determined
Securing Reserve for 50 Year Operations
Block model preparation
Final Raw Mix Well Defined
Recommended Area to Apply Step III
3-D topographic surface
from survey work
Pit design combined with
topographic surface
Block model created
within the pit design
Block model with
estimated quality
displayed
Objective :Details Study on the Quarry Area to Elaborate
Successful Mining Plan Suitable for Plant Requirements
Scope of Work:
Preparation of Detailed Contour Maps (1:1000)
Core Drilling (Narrow Spacing )on Area Sufficient to 10 Year
Complete Chemical Analysis & Physical Tests
Evaluation of the Results and block modeling
Elaboration of Mining Plan including opening details
Report Preparation
Block model filled with chemical data
Attribute data
assigned to each
block
High-grade limestone
• Silica Distribution
Estimated CaO (%) Distribution
within Limestone 1 Horizon
Estimated MgO (%) Distribution
within Limestone 1 Horizon
Block Model Report
Volume and Tonnage of
Rock units Block Model Report
Volume, Tonnage and Chemistry
of Rock units
• Inventory of the deposit
Conclusion:
The Area of 10 Year Exploitation Well Defined Qualitative &
Quantitative
Securing a Continues & Stable Feed of Raw Material
Optimization of All Quarry Operation
Definition of Quarry Equipment List
Definition of Yearly Exploitation Figures
Figure for year 1
on bench 1
Figure for year 2
on bench 1
Figure for year 3
on bench 1
Thank You