* All fees are exclusive of vat
** PREMIUM - Customize your learning experience
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?
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.
Explore & Practice
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.
Process and kiln system design
Raw Material characteristics
Chemical Reactions in the Kiln
Liquid Phase and importance of
Iron and Aluminum content
Fuel types and their characteristics
Alternative fuels use in the calciner
and impact in system operation
Main burner, changes that affect flame formation and lead to better burning conditions
Clinker cooler types
Cooler operating philosophy and
optimization of clinker coolers
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
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
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
System cooling down
Loss of fuel in the calciner / or kiln burner
High bed depth in the cooler
Change in pressure profiles in the Preheater
Main Bag House issues
Kiln Ring formation / Kiln ring fall
Kiln system shut down
Considerations during a short shut down
Considerations during a maintenance shut down
Evaluation running the kiln system to full production.