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: June 10, 2024



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.


Learning Outcomes

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.


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.


Learning Path

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.

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