This exciting program offers a myriad of cement process/production topics covered over three days of training by cement industry experts. Topics will range from the theoretical to the practical – such as kiln operations, sampling theory, and emissions. Continuing education credits will be available for each course on an individual basis. Four (4) modules (of different topics) will be offered each day and each module will consist of a one hundred and five (105) minute presentation.
While the focus of the overall training is specifically tailored to process engineers and production managers at the factory level, any given module may prove to have practical merits for any number of cement plant personnel – including cement chemists, purchasing managers, quality engineers, and aspiring plant managers.
There will be a charge of $50 per session, however, you can purchase all four (4) modules on a given day for $150. You can also purchase access to all of the modules for $450. All module purchases are nonrefundable. To sign up for Process Training modules simply click on the desired modules or module package during the registration process.
The modules will be presented on Monday, May 22, 2017, Tuesday, May 23, 2017 and Wednesday May 24,2017. Below is a list of the module topics, dates and times. Simply click on the topic to see a description of the session contents.
Sampling Theory (Monday, 8:00am - 9:45am)
Discusses proper sampling techniques, ensuring that samples are representative, and explores common sampling issues and errors.
Raw Mix Design (Monday, 10:15am - 12:00pm)
Discusses the common raw materials in use for cement manufacture as well as factors to consider in mix design.
Process Equipment & Measurements (Monday, 1:00pm - 2:45pm)
Discusses the common equipment used for process analysis and how to use the equipment. It will cover classic equipment such as temperature and pressure probes, but also review newer technologies, such as infrared imaging, etc.
Emissions (Monday, 3:15pm - 5:00pm)
This session reviews the gaseous emissions from cement manufacturing including NOx, SOx, CO, HCI, THC and mercury. Sources of emissions and an overview of control technologies will also be offered.
Preheaters (Tuesday, 8:00am - 9:45am)
This session will cover the design and operation of the preheater and precalciner. It will also review the proper operation and trouble shooting for preheaters.
Kilns (Tuesday, 10:15am - 12:00pm)
Review the operation of the kiln and the factors that impact proper kiln operation. Topics include the clinkering reactions, kiln coating, rings and balls.
Coolers (Tuesday, 1:00pm-2:45pm)
This session reviews the evolution of design from second generation to third generation coolers. It also will review the primary control and operating features of the modern cooler and provide trouble shooting guidelines for cooler operations.
Heat Consumption (Tuesday, 3:15pm-5:00pm)
This session reviews the theoretical heat of reaction for producing clinker and reviews the sources of heat and heat losses in the clinkering process. It will also provide guidance for identifying areas of heat loss and control mechanisms.
Crushing & Prehomogenization (Wednesday, 8:00am-9:45am)
Discusses the basics of raw material extraction and preparation for processing in the plant. Covers quarry blast fragmentation and optimization to primary and secondary crushing. The evolution of quarry and crushing equipment will be covered as well as the design and operation of prehomogenization piles.
Horizontal Mills (Wednesday, 10:15am-12:00pm)
Reviews the basics of operation for ball mill circuits. The focus will be on cement milling but with reference to raw ball mills as well. Mill operating and trouble-shooting concepts are covered as well as separator design and operation.
Vertical Mills (Wednesday, 1:00pm-2:45pm)
Design and operation of vertical mills for raw material, coal, and cement grinding. Reviews the common issues with operation and fine tuning of vertical mills.
Power Modeling (Wednesday, 3:15pm-5:00pm)
This session develops a power consumption model for an existing plant that can be used to estimate current and future power consumption. The basics for establishing a power model for any and all cement plants will be reviewed as well as how to use and fine tune the model.