AN INTRODUCTION TO THE CEMENT MANUFACTURING
Online Learning Experience
Imagine an online classroom that takes you to learn at your own pace, allowing more choices with your learning opportunities. The Cement Institute is dedicated to providing the most dynamic and engaging programs available, as our enhanced online experience demonstrates an interactive and hands-on knowledge applicable directly to your plant.
Start Date: November 4, 2023
This Course is scheduled to be available on the following date(s):
A 2-week modular course is designed for engineers or technical degreed persons and newly hired in the cement industry. It is also intended for engineers or technical degreed persons already working in the cement industry, whose work experience has not required in-depth knowledge of the cement process, or those who want a comprehensive understanding of the entire cement manufacturing process.
The course’s first objective is to give an overview of the process chain within the cement industry. All the main processes involved during cement production will be discussed, including the extraction and processing of raw materials, the combustion process, cement grinding, quality control and storage, and cement distribution.
Module 1: An introduction to Cement Manufacturing.
This module addresses the fundamental principles of cement production.
Module 2: Raw materials for cement manufacture.
In the cement industry, the quarry is the extraction method for producing raw materials in the cement manufacturing process. Quarry extraction describes the extraction of rocks on the surface, while open-pit extraction describes minerals’ extraction on the surface. Discontinuous mining systems, such as scraping, tearing, crushing, and blasting, are commonly practiced in limestone quarries. Continuous mechanized mining systems are used, with chain or bucket wheel excavators, where deposits are consistent and soft, such as chalk.
This module introduces the typical raw materials for the cement process and the basic calculations necessary to proportion raw materials to achieve the clinker’s required chemistry. The raw mix module concept as a method of control is presented along with the expected ranges.
Module 3: Pyroprocessing
The combustion process is carried out in two stages: calcination and sinterization.
Fuels with a high calorific value are used in the combustion process. Conventional fuels, such as coal and fuel oil, are increasingly being replaced by alternative fuels, such as used tires, processed plastics, and sewage sludge.
Module 4: Cement Grinding Systems and Dispatch
Cement clinker is grinding in roller mills and ball mills, such as granulated blast furnace slag, fly ash, limestone, and approximately 5% sulfate agents (e.g., gypsum).
During production and before leaving the plant, the cement is internally inspected and tested in the plant’s laboratories.
Who is this course for?
This course is designed for engineers or technical degreed persons and newly hired in the cement industry. It is also intended for engineers or technical degreed persons already working in the cement industry, whose work experience has not required in-depth knowledge of the cement process, or those who want a comprehensive understanding of the entire cement manufacturing process.
Individual responsibility is vital for reaching usable technical conclusions and presenting their results to obtain a course certificate.
Topic 1: Plant Safety
Topic 2: An emphasis on special Hazards During the Cement Production Phases
Topic 1: Introduction to the History of Cement
Topic 2: Portland Cement Manufacturing
Topic 3: Cement Manufacturing Processes
Topic 4: Process Control in the Cement Industry
Topic 1: Raw Materials Extraction/Quarry Operations
Topic 2: Crushing
Topic 3: Prehomogenization and Storage of Raw Materials
Topic 4: Raw Grinding Systems
Topic 1: Process Requirements for Kiln Systems
Topic 2: Process Types
Topic 3: Homogenizing and Kiln Feed
Topic 4: Precalcining Systems
Topic 5: Kiln Systems
Topic 6: Firing Systems
Topic 7: Clinker Coolers
Topic 1: Cement Grinding in Tube Mills
Topic 2: Cement Chemistry
Topic 3: Grinding with Vertical Roller Mills
Topic 4: Dust Collector
A unique combination of theoretical and practical skills throughout this course will be learned, which will help you develop and execute the concepts and technical knowledge acquired in the daily activities. The following downloadable materials are part of the course to enhance and facilitate the participants’ learning experiences.
Participant manual: Include the key concepts, definitions, and activities presented in this course.
Work section book: Provide learning activities and hands-on practice – case study and exercises. Solutions are included after each training is completed. Certification is achieved by completing a satisfactory level of exercises, quizzes, and final exams for each module.
The course is conducted online, allowing students flexibility (within two weeks) to complete all modules. Students should expect to spend more than 10 hours per week and some additional time for private reading/study. A computer with Internet access (broadband recommended) and email will be required.