* All fees are exclusive of vat
** PREMIUM - Customize your learning experience
Course Description
The pyroprocess system is considered the heart of the cement manufacturing process. It is also where most of the thermal energy is used.
The pyroprocess operations and simulation seminar offers a thorough study of the design and function of the kiln systems, including but not limited to the latest methods for optimisation and proposals for upgrades and modernisation of the current system.
The seminar will focus on the understanding of how the pyro system works, the influence between the burnability of the raw materials and the operating strategies. The relationship between the chemistry of the raw materials, fuels, burner settings and operation of the preheater/calciner/kiln/cooler systems.
What Do Participants Learn?
- Understanding of how the system is designed to operate.
- The relationship between the raw feed chemistry, fineness, fuel characteristics, burners and flames, kiln operation efficiency and clinker quality.
- The effect of operating techniques and manufacturing costs.
- How to analyse and troubleshoot kiln systems and identify areas for improvement with system upgrades and modernization options to improve operations and productivity.
- Improved synergy in between the production, quality and maintenance departments for better communications and cooperation.
Who Should Attend?
- CCR Operators and site operators
- Production Engineers and Mechanical Engineers
What Will the Learning Experience Include?
Phase: 1
Introduce
- Comprehensive pre-program activities include:
- Web-based information forms & surveys completed by attendee.
- Direct consultation with the attendee about the expectations.
- During the training, participants engage in data, activities, and conversations that lead to insight and knowledge.
- Participants learn from expert trainers who have both academic and business experiences.
- Highly applicable training content & instructive activities for adding depth to training topics.
- **A half-day site visit for integrating the experience & plan next steps. Opportunities to provide connections, ideas & support.
Phase: 2
Explore & Practice
Phase: 3
Apply
- Apply & sustain the learning experience by using this ongoing support:
- To ensure participant has new skills or behavior progress.
- Optional, fee-based mentoring & coaching with the trainer.
- Training materials & additional documents (e-books, pdf files, presentations and articles)
- Evaluate your training experience by giving us feedbacks and help us to reach our organizational goals.
- Participant's Evaluation
- Trainer's Evaluation
Phase: 4
EVALUATE
Section 1:
- Kiln Operation
- Process and kiln system design
- considerations
- Kiln Zones
- Raw Material characteristics
- Chemical Reactions in the Kiln
- Liquid Phase and importance of
- Iron and Aluminum content
- Calciner operation
- Fuel types and their characteristics
- Alternative fuels use in the calciner
- and impact in system operation
Section 2:
- Combustion Theory
- Heat transfer
- Flame formation
- Main burner, changes that affect flame formation and lead to better burning conditions
- Clinker coolers
- Clinker cooler types
- Cooler operating philosophy and
- optimization of clinker coolers
Section 3
- Heat Balances
- Heat and Material flows
- Measurements in the pyro process system (temperature, pressure, O2 profile
- Measurements in the cooler,airflows, temperatures and pressures
- Heat Balance calculations
- Optimization of heat consumption
- Kiln Feed Burnability
- Distribution of air and losses in the cooler
- Clinker formation
- Behavior of volatile matter
- Volatile matter work session
- Emissions of NOx, SOx, particulates,
- mercury etc from cement kilns
- New emission standards
- Bag House, operation and maintenance
Section 4:
- Refractory Considerations.
- Practical sessions with the Use of
- Pyroprocess Simulation / ECS Cemulator software
- Starting and Stopping the kiln using the ECS Cemulator software
- Interaction of Control Loops between the Kiln and Cooler areas
- Various Disturbances
- System cooling down
- Loss of fuel in the calciner / or kiln burner
- High bed depth in the cooler
- Kiln push
- Change in pressure profiles in the Preheater
Section 5:
- Main Bag House issues
- Kiln Ring formation / Kiln ring fall
- Cyclone plug
- High CO
- Kiln system shut down
- Considerations during a short shut down
- Considerations during a maintenance shut down
- Evaluation running the kiln system to full production.
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