21 - 24 October 2024 Dallas, Texas



The training aims to identify and comprehend all the necessary information about the completed pyroprocessing system – both known and unknown. The seminar includes exercises and case studies to supplement the lectures, which help participants relate the seminar material to their cement pyroprocessing facility. This understanding will enable them to meet the changing needs of cement producers and customize solutions accordingly. The seminar covers several topics, such as optimizing output, improving efficiency and reliability, and reducing production costs.


The outcome of the training will be as follows:

During the Pyroprocess Operations and Maintenance training, participants will acquire the necessary knowledge, understanding, and job-related skills to handle and comprehend the technology and equipment delivered. The process of technology transfer will be completed in a way that directly relates to the operation and maintenance of the equipment. 

  • Maintenance and process consideration – best practices.
  • Optimize and standardize operation and maintenance techniques, improving the overall equipment efficiency.
  • Review and implement the most efficient operation and maintenance practices to achieve a sustainable and stable run time in the system.



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 operation and maintenance.



“The seminar is designed for operation and maintenance personnel.”

Aims of the seminar

It is important to understand the pyroprocess technology system, including Raw Mix Design, Burnability, and Clinker Quality, and to optimize Heat Consumption. Additionally, Operation and Process Diagnostic Studies should be conducted to enhance the productivity of Clinker Production. Energy Conservation and Energy Audit in Pyro Systems, Refractory and Management Practices, and the Impact of Raw Mix on Coating and Build-Ups and Refractory Performance should also be considered. The process should also include Chemical Clinker Analysis and improvement of Burnability Through the Use of Mineralizers. A Techno-Economic Assessment should be conducted to evaluate the overall impact.

It is also important to understand Kiln maintenance technology, including Kiln alignment, measurement, and consequences of the kiln shell temperature. The optimization of the kiln run factor, evaluation of kiln behavior based on kiln operation and process diagnostic, and the Impact of the Burnability and kiln reliability should also be assessed. Kiln maintenance activities should be evaluated, analyzed, and developed based on failure mode equipment analysis.

Recognizing the importance of life-cycle and kiln reliability and establishing the right maintenance program represents a key element to achieving an optimal kiln run factor and performance.

An accurate and continuous method of measuring student progress and knowledge is required, which involves graphing and analyzing technical and conceptual data. This will provide the staff and organization with the necessary tools to respond effectively to the needs of the plant and current and future demands. The aim is to help operation and maintenance personnel improve the productivity, efficiency, performance, and quality of the workforce.  This can be achieved by anticipating and eliminating possible delays through understanding and identifying the critical elements that impact the pyroprocess performance and system reliability.


  • Continuous education
  • Advanced techniques and new skills
  • Stay competitive
  • Enhance teamwork
  • Improve maintenance quality and productivity
  • Keep updated with industry developments
  • Improvements in overall plant performance
  • Gain new knowledge
  • Develop new skills


  • Welcome And Plant Safety

  • Process Requirements for Kiln Systems

  • Process Types

  • Homogenizing and Kiln Feed

  • Kiln Systems

  • Precalcining Systems

  • Chemical Reactions in the Kiln
  • Firing Systems
  • Safe Handling of Coal
  • Burners and Flame
  • Combustion Engineering
  • Fuel Types and their Characteristics
  • Alternative Fuels
  • Influence of Manufacturing Parameters on Clinker Properties
  • Volatile Matter
  • Influence of Operating Parameters
  • Kiln Control and Operation
  • Heat Balance
  • Clinker Coolers
  • Cooler Control Philosophy
  • Fans System
  • Emissions from Cement Kilns
  • Optimization of Heat Consumption
  • Operation and Maintenance KPIs
  • Kiln Maintenance Introduction – RCA & FMEA
  • Kiln Shell Specification
  • Kiln Shell Deformation
  • Measuring Kiln Shell Deformation
  • Kiln Shell Mechanical Consideration
  • Cutting & Replacement of Kiln Shell Section
  • Kiln Alignment (Kiln Axis)
  • Horizontal & Vertical Axis Deviation
  • Kiln Loads, Pressures, Stresses
  • Kiln Bearing Types
  • Bearing Liners
  • Bearing Lubrication
  • Kiln Support Piers
  • Kiln Support Rollers
  • Kiln Axial Balance
  • Kiln Roller Adjustment
  • Kiln Roller Calculation
  • Tire Clearances & Tangential Tire
  • Ovality
  • Tire Mounting and Filler Bar Design
  • Correcting Ovality
  • The Gear and Pinion (Gear Basics)
  • Horizontal & Vertical Axis Deviation
  • Gear Installation and Alignment
  • Lubrication
  • Maintenance and Troubleshooting
  • Kiln Inlet Seal and Outlet Seal
  • Thrust Roller
  • Solutions to Problems in Kiln Mechanical Performance
  • Kiln Preventive Maintenance Checklist


enroll now

21 - 24, OCTOBER 2024


Learn more


555 Evergreen St, Dallas, TX 75201

Registration fee per participant: $2,500 USD. Taxes may apply.

The fee includes all training materials, certificate, welcome cocktail, coffee breaks, daily lunches, and farewell dinner.

Payment will be accepted via Credit Card or Purchase Order.

Note: This does not include the cost of your travel expenses, lodging, or personal expenses.

An invoice will be forwarded to you after receiving your registration for a seminar or training course.

Registration is not considered final until payment is received

  • If the participant wishes to cancel his/her participation any time before 61 days of the scheduled seminar date, the participant will
    receive a 100% refund or can decide to receive a credit note of the entire amount, valid for one year from the date it is issued and
    can be used for any future training organized by The Cement Institute, LLC.
  • If the participant wishes to cancel his/her participation any time from 31 to 60 days of the scheduled seminar date, the participant will receive a 50% refund.
  • If the participant wishes to cancel his/her participation any time from 0 to 30 days of the scheduled seminar date, the invoice amount is fully payable.

The Cement Institute reserves the right to change the content, change the dates of the training or cancel seminars and training courses if there are not enough participants to meet the objectives of the seminar or training course as well due to acts of terrorism, extreme weather condition or any event beyond the control of  The Cement Institute, LLC. In case of cancellation, a notification will be sent directly to all applicants.
The Cement Institute, LLC cannot be held responsible for any cost, damage, or expenses that may be the customer due to the event being postponed or canceled. The training fee does not include travel costs, hotel accommodation, or transfer of insurance.

Tel: +1 917 937 8067