PYROPROCESS TECHNOLOGY COURSE
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: October 2, 2023
This Course is scheduled to be available on the following date(s):
A 6-week modular course designed to give the course attendee a solid understanding of the Pyroprocess system.
The purpose of training the personnel is to create a timely availability of an adequately trained plant staff. This will be done by developing and creating a training program that will sufficiently train the participants by conducting a pyroprocessing training with necessary theoretical presentations to acquaint the personnel with the technology and procedures for operating pyroprocessing systems, including preheater, calciner, kiln, and clinker cooler. It is the intention to provide the participants with knowledge, skills, and understanding of cement production technology concerning:
- Equipment operation and processes such as the Kiln, Preheater, Calciner, and Burner and Cooler
- Interlocking and control loops
- Control philosophy and controls of the systems
- Safety and Hazard Awareness while operating equipment
- Process Control and Automation
The course consists of theoretical classroom training, exercises, case study, and a work section.
An emphasis on the understanding of the pyroprocess 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.
The basic cement kiln system comprises a preheater in which feed material is prepared by heat exchange with hot exhaust gas, a fired rotary kiln in which the clinkering reactions occur, and a cooler in which the hot clinker exchanges heat with ambient combustion air.
The kiln system has to be designed to cope with the chemical process requirements during which the kiln feed material is converted into cement clinker.
This process as a whole is endothermic and takes place at maximum material temperatures of 1450 °C. Receiving its thermal energy from hot gases of up to 2000 °C generated by combusting fuels is also referred to as pyroprocess.
Type of reaction and temperature development is compiled in “sequence of reactions occurring in a rotary kiln” (table 1) and graphically as the “quasi-qualitative variation of minerals with temperature.”
Kiln feed is subject to successive reactions as its temperature increases:
- 100 °C Evaporation of free water
- 500 °C Evolution of combined water
- 900 °CCaCO3 -> CaO + CO2
- 900 °C Reactions between CaO and Al2O3, Fe2O3 and SiO2
- 1200 °C Liquid formation
- 1280 °C Formation of C3S and the complete reaction of CaO
The chemical process taking place in the kiln system where raw meal (input) is converted to cement clinker (output) can be subdivided into the following five steps:
Process and equipment have been developed and improved to perform these steps forever improved economy, which means:
- High availability
- Low heat consumption
- Low power consumption
- Higher unit capacity
- Stable kiln operation
- Good, uniform clinker quality
Effect of the Training
The outcome of the training will be as follows:
The process of technology transfer, related to the areas mentioned above, will have been completed in such a way as to be directly relevant to the running and operation of the equipment.
The Pyroprocess Operations training participants will acquire knowledge, understanding, and job-related skills, which will enable them to handle and comprehend the delivered technology and equipment.
Who is this course for?
This course is primarily intended for process engineers, operators, and production personnel working in a cement plant.
Individual responsibility is vital for reaching usable technical conclusions and presenting their results to obtain a course certificate.
Topic 1: A refresher of general plant safety overview
Topic 2: An emphasis on special Hazards During the Cement Production Phases
Topic 1: Process Requirements for Kiln Systems
Topic 2: Process Types
Topic 3: Homogenizing and Kiln Feed
Topic 1: Chemical Reactions in the Kiln 1
Topic 2: Chemical Reactions in the Kiln 2
Topic 3: Chemical Reactions in the Kiln 3
Topic 1: Kiln Systems
Topic 2: Precalcining Systems
Topic 3: Kiln Maintenance Introduction
Topic 1: Firing Systems
Topic 2: Safe Handling of Coal
Topic 3: Burners and Flame
Topic 4: Combustion Engineering
Topic 5: Fuel Types and their Characteristics
Topic 6: Alternative Fuels
Topic 1: Influence of Manufacturing Parameters on Clinker Properties
Topic 2: Volatile Matter
Topic 3: Influence of Operating Parameters
Topic 4: Kiln Control and Operation
Topic 5: Heat Balance
Topic 1: Clinker Coolers
Topic 2: Cooler Control Philosophy
Topic 1: Fans System
Topic 2: Emissions from Cement Kilns
Topic 3: Operation KPI’s
Topic 4: Optimization of Heat Consumption
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 exercise 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 six 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.