Training Solutions

Objectives:

Introduction to cement chemistry, clinker mineral composition, impact of chemical elements on clinker & cement performance and cement SO3 content & gypsum dehydration.

Topics Covered:

Moduli calculations & impact of each, clinker mineral composition calculations & impact of each, types of cement clinker produced, impact of minor chemical elements on clinker & cement quality, liquid phase calculations & impacts, kiln coating, clinker grindability, cement types produced, analysis of cement, cement hydration, role of gypsum in cement, optimum cement SO3 content, types of gypsum and gypsum dehydration.

Objectives:

History of cement kilns, what happens inside a cement kiln, different kiln processes and kiln performance specifications.

Topics Covered: 

Reactions inside a kiln, historical development of cement kiln technology, advantages & disadvantages of different kiln systems, calculations for kiln inclination, volume loading, burning zone thermal loading & kiln residence time.

Objectives:

Assess thermal efficiency, assess material balance & quantify energy losses.

Topics Covered:

Standard measurements to be done, steps involved when conducting a heat balance, measurement equipment, heat balance boundary, material samples & analysis required, clinker discharge temperature measurement, material stream heat capacities, gas stream measurements & heat capacities, radiation & convection measurements & calculations, overall material & gas stream mass and energy balance, clinker reaction energy calculation, cooler material and gas stream mass and energy balance, assessment of heat balance, factors impacting of heat consumption, ingress air measurements/calculations & kiln seals.

Objectives:

Function of grate cooler, typical operating parameters and typical problems experienced during operation.

Topics Covered:

Suppliers, advantages & disadvantages of grate coolers, working principle, performance parameters, cooling rate impact on clinker quality, recuperation efficiency, specific aeration rates, clinker residence time & bed height, problems experienced (i.e. snowman formation, red rivers, etc.), cooler control philosophy, cooling fan particulars & online flow measurement, cooler fan table & impacts of cooler operation on kiln system operation.

Objectives:

Control variables, impact of adjustments and kiln start-up.

Topics Covered:

Uncontrolled and control variables, control signals from system, impact of operating parameter adjustments, requirements for kiln system stability, kiln heat-up philosophy.

Objectives:

Review grinding efficiency of different technologies, mill capacity requirements, system selection, new grinding machines.

Topics Covered:

Size reduction efficiency, mill capacity requirement calculation, comparison between different grinding technologies.

Objectives:

Operation, material & gas steams, hydraulics, wear, specific electrical energy consumption & production rate and different VRM suppliers.

Control targets, signals & adjustments, vibration control, operational control, impact of control parameters and control loops.

Topics Covered:

Grinding mechanism, mill components, material streams inside VRMs, maximum/minimum feed size, feed chute entry, material flow on grinding table, impact of dam ring height, roller profile impact, impact of nozzle ring & armour ring, required gas flow rate, areas of ingress air, hydraulic force calculations, accumulator pressure settings, mill motor power calculation, grinding friction factor, table speed, wear measurement, specific electrical power vs. product fineness, features of different mill suppliers.

Requirements for mill control, control loops necessary and impact of operating parameters.

Objectives:

Types of separators, design criteria and analysis of separators.

Topics Covered:

Separator operation, types, requirements based on mill circuit, Tromp curve plotting & analysis, dynamic seal arrangement, separator loading, impact of separator settings, Rosin Rammler plot, static guide vanes and separation gap.