Ethiopia - i-Capital Africa in Ethiopia and Sudan for the exploration of precious and ... Feeding of kaolin, gypsum & white sand El-Minya White Cement (Italicement)

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