Learning outcomes 

An emphasis on the understanding of the pyro-process technology system: – raw mix design, burnability and clinker Quality – optimization of heat consumption – operation and process diagnostic studies and productivity enhancement of the clinker production – energy conservation and energy audit in pyro system – refractory and management practices – Impact of raw mix on coating and build-ups and refractory performance – chemical clinker analysis – Improvement of burnability through use of mineralizers, techno-economic assessment.

Hands-On Practice

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 of process and operation.

Course Contents

Providing details of the processing equipment of cement kiln systems – Safety and Process Control of Cement Kiln –Standard operation procedures – Alkali Bypasses – Chemical Reactions and analysis – Rotary Kiln – Raw Material characteristics – Alternative Fuel – Energy Conservation and Energy Audit – Calciner Reaction – Calciner Fuels – Process Diagnostic Studies and Productivity Enhancement – Developmental trends in pre-heaters, pre-calciners, kilns, burners and grate coolers – Developments in refractories and refractory management.

Clinker coolers – Emission standards – Applications of optical microscopy in cement industry – Chemistry of clinker burning – Pre – Post tests.

Method

The course consists of theoretical classroom training, exercises, case study, work section, and calculations.

Documentation

To enhance and facilitate the participants’ learning experiences, the following materials are part of the course package:

• Participant manual:
• Include the key concepts, definitions, and activities presented in this course.
• Work section book:
• Provide learning activities and hands-on practice. Solutions are included after each exercise for direct feedback.