Energy Management in Cement Plant Mills with Optimize Plan for Extraction and Blending of Mining Zones

Considering the consumption of more than 25% of energy by raw mill materials in cement plants, providing a suitable plan for blending different mining zones can be an effective approach in reducing the energy consumption. The purpose of this paper is optimizing the plan of blending limestone mining zones to reduce milling energy consumption raw mills (ball mill and HPGR). The geomechanical properties of different mine zones have been identified by performing the bond work index, drop weight, and uniaxial compressive strength (UCS) tests. Also, to comply with cement production standards, cementing modules including S.I.M, A.L.M, and L.S.F have been calculated for different mine zones. Mining production planning with the aim of achieving the minimum comminution energy and transportation costs has been developed by the Goal programming method. Planning constraint equations are also considered to regulate cement modules. Finally, utilizing windows Quantitative System for Business software, the necessary calculations have been carried out. Based on the results, the extraction order and blending values of different mine zones are adjusted regarding cement modules and minimizing transportation costs, leading to a reduction in energy consumption of raw mills.