Optimum Utilization of Low-Grade Limestone by Modified Blending Method to Achieve Required Lime Saturation Factor in Cement Industry: A Sustainable Mining Approach in Sadhera and Salaiya Limestone Mines, Madhya Pradesh

Abstract

The consumption of limestone in India has increased dramatically over time, under the impression of sprawling urban spheres and expanding industrial applications in cement industry. This elevated demand has posed India as the largest importer of limestone globally sourcing materials from various countries. The main objectives of the current study are to conduct geochemical analysis of the ore body and to develop a modified blending plan to optimize utilization of low-grade limestone. The study emphasizes on the importance of selective mining, proper blending, and sustainable extraction practices to maximize resource efficiency while minimizing environmental impact. In the current study borehole data of two limestone mines Sadhera and Salaiya were employed for proper utilization of low-grade limestones. The distribution of CaO content exhibits remarkable variation along the deposit with minimum value at 34.14% upto 50% as highest value at Sadhera mine while these values range between at 40.26% to 43.84% Salaiya mine. As per the IBM, threshold values for CaO and MgO are 34% and 5% respectively which can be attained by strategic blending of low- and high-grade limestones. For Sadhera and Salaiya mines, the statistical analysis depicts CaO exhibiting negative skewness in normal distribution. Also, the correlation analysis exhibits strong correlation of CaO with SiO₂ and Al₂O₃. The modified beneficiation method represents a substantial 49% and 12% increase for Salaiya and Sadhera mines indicating towards improvised quality criteria, extended mining limits, or inclusion of low-grade zones earlier ignored in the mining operations. The modified LSF of 149% and 112% indicates a comprehensive reevaluation of the resource potential, with possible incorporation of improved updated economic factors. The findings of the study revealed an overall 25% increase in resource estimation, indicating the presence of deeper and previously unaccounted reserves. Such analysis plays a vital role in guiding efficient extraction planning and optimizing resource utilization. The inclusion of marginal limestone deposits along with the revised evaluation techniques and blending methodologies offers an overall enhanced mineral recovery across the mining sites. Such enhancement of mineral utility ensures not only longevity of the mine life but also results in significant reduction in overburden and inter-burden waste leading to sustainable mining practices.