Advanced Process Technology of Cement Manufacturing

Introduction

This course is designed to provide participants with a detailed and up-to-date overview of cement manufacturing process technology and standards. It covers the cement plant process and chemistry including pyro-processing, communication engineering, silos & homogenization, heat balance and circulation phenomena, refractories and process control, etc. The Kiln process and systems, and the chemical reaction in Kiln Zones. Further, the course will also discuss the effects of the composition of Kiln charge, the theory of clinkering, the rings and build-up in the manufacturing including the wet and dry Kiln process, clinker coolers and the operations and the optimization of clinker coolers, the cement manufacturing standards including raw materials, liquid phase, fuel types, gas analyzers, new emission, and new source performance standards, the optimization techniques of heat consumption, and the principles of microscopic analysis and API classification of Portland 

Objectives

By the end of the training course, participants will learn to:

• Apply and gain an in-depth knowledge of cement manufacturing process technology and standards.
• Discuss cement process and chemistry pyro-processing, commination engineering, silos & homogenization, heat balance and circulation phenomena, refractories, and process control, etc.
• Carry out kiln processes and systems and recognize chemical reactions in kiln zones.
• Recognize the effects of the composition of kiln charge and employ the theory of clinkering as well as the ring build up in the cement process.
• Enumerate the different types of cement processes in the manufacturing including wet and dry kiln processes, clinker coolers as well as the operations and the optimization of clinker coolers.
• Identify cement manufacturing standards including raw materials, liquid phase, fuel types, gas analyzers, new emission and new source performance standards.
• Employ optimization techniques of heat consumption as well as the principles of microscopic analysis and API classification of Portland cement.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practices. Participants will have the opportunity to share with the facilitator and other participants what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS Teams/ClickMeeting.

Who Should Attend?

This course provides an overview of all significant aspects and considerations of cement manufacturing process technology and standards for newcomers to the cement industry including fresh graduate engineers, technologists, technicians and those managers who are new to the industry. Further, the course will serve as a refresher for experienced managers, engineers, supervisors and other technical and non-technical staff.

Course Outline

Module 1 - Objectives of cement manufacturing fundamental requirements of the cement product in application.Lectures in this module:

• Session 1.1 - History of Cement
• Session 1.2 - Cement demand
• Session 1.3 - Cement Industry Characteristics
• Session 1.4 - Customers’ Requirements
• Session 1.5 - Chemical and Mineral Composition
• Session 1.6 - Clinker Combination & Hydration
• Session 1.7 - Cement Types and Applications

Module 2 - Raw materials for cement manufacture exploration, extraction, processing and mixing of cement raw materials. Lectures in this module

• Session 2.1 - Raw Materials for Cement Manufacturing
• Session 2.2 - Raw Material Proportioning
• Session 2.3 - Crushing and Blending
• Session 2.4 - Raw Material Storage & Blending
• Session 2.5 - Raw Milling Systems
• Session 2.6 - Kiln Feed Homogenisation
• Session 2.7 - Combined Kiln & Raw Mill Systems

Module 3 - Pyroprocessing 1 - Chemical, physical and mineralogical transformation from raw mix to cement clinker. Lectures in this module:

• Session 3.1 - Pyroprocessing
• Session 3.2 - Combustion in the Kiln
• Session 3.3 - Precalcination
• Session 3.4 - Cooling the Cement Clinker

Module 4 - Pyroprocessing 2 - Process and equipment evolution for cement clinker manufacture. Lectures in this module:

• Session 4.1 - Venting exhaust gases from the kiln
• Session 4.2 - Alkali Cycles
• Session 4.3 - Emissions Mitigation
• Session 4.4 - Mass and Energy Balance of the Kiln

Module 5 - Cement grinding and dispatch. Finishing the cement manufacturing process and satisfying the end customer. Lectures in this module:

• Session 5.1 - Developing Fineness
• Session 5.2 - Classification and Separation
• Session 5.3 - Gypsum dehydration and temperature control
• Session 5.4 - Blended cements, grinding aids and quality improvers

Module 6 - Sustainability in cement manufacture. Meeting corporate, customer, social and environmental obligations in the manufacture of cement. Lectures in the Module:

• Session 6.1 - Essential Services
• Session 6.2 - Sustainability
• Session 6.3 - Quality Assurance
• Session 6.4 - Manpower