Visitors :4062 Org
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Month : 174 UsersSylabus Process/Production Section
1. Mining Operation (3 days)
§ Quarry exploitation plans
§ Quarry scheduling optimization
§ Government quarry safety regulation
§ Exploration method
§ Rehabilitation system
§ Drilling & blasting techniques
§ Management of mobile equipment
§ Loading and hauling techniques
§ Mine surveying
§ Road maintenance
§ Overview of hydraulics, mobile plant
§ Equipment related safety
§ Contracting out the quarry operation
§ Quarry development
§ Technique Revegetation and Reclamation
2. Cement Manufacturing Course Level 1 (3 days)
§ Quarrying Operation
§ Crushing and Pre homogenizing
§ Raw Grinding Systems
§ Coal Mill
§ Kiln Systems : SP, Kiln, Cooler
§ Refractory
§ Cement Grinding
§ Cement Chemistry
§ Bag Plant
§ Pollution Control
§
3. Cement Manufacturing Course Level 2 (5 days)
§ Quarrying Operation
§ Crushing and Pre homogenizing
§ Bulk Solid Storage
§ Grinding/Comminution Engineering
§ Separators
§ Coal Mill Systems: Operation, Parameters, Trouble
§ Raw Grinding Systems : Operation, Parameters, Trouble
§ Burners and Flames
§ Combustion Engineering
§ Alternative Fuels
§ Circulation Phenomena
§ Kiln Systems Operation Principles, Parameters, Trouble
§ Refractory Technology
§ Mass and Heat Balance of Kilns System
§ Mass and Heat Balance of Mill System
§ Cement Grinding Systems : Operation, Parameters, Trouble
§ Grinding Media
§ Main Fans
§ Raw Mix Design
§ Cement Chemistry
§ Quality Control
§ Dedusting System
§ Gas Analyzing Systems
4. General Safety Training (3 days)
§ Awareness of HSE Management System
§ Company safety policy
§ Safety procedures
§ Emergency procedure
§ Emergency response : fire, earthquake, bomb treat
§ Fire extinguisher
§ First aid procedures
§ Incident investigation
§ Safety observation
5. Specific Safety Training (3 days)
§ Electrical Safety
o Power on/off procedure
o Lock out procedure
o Starting procedure
§ Mechanical Safety
o Materials and equipment lifting procedure
o Welding safety
o Tools machining safety procedures
o Fire Extinguisher
§ Hazard Identification & Risk Assessment
§ Lock off procedures
§ Equipment entry procedures
§ Handling flammable materials
§ Safety Induction Development
§ Personal Protective Equipment (PPE)
o Usage Procedure and Monitoring
§ Safety Inspections on
o Construction Equipment
o Chemicals
§ Heavy equipment mobile plant safety
§ Drilling and blasting safety
§ Hazard Identification & Risk Assessment
§ Work permit system
o Convince space
o Hot work Lock Out Tag Out (LOTO)
o Scaffolding
o Job Safety Analysis
§ OSH Expert
§ Monitoring and Measurement
§ Ambient air measurement, noise mapping, vibration mapping
§ Equipment certification
6. Environment System Management (3 days)
§ ISO 14000 standard
§ Environmental Aspects
§ Monitoring and Measurement
§ Impact Analysis
§ Environmental Auditing
§ Explosive Materials
§ Inspections of emission including noise, vibration, dust
§ Emission Monitoring and Reporting
§ Waste Material Handling
§ Environmental Management Program
§ Environmental Regulation
§ Hazardous Material Handling
§ Destruction Removal Efficiency
§ Auditor training
7. Quality Management System (3 days)
- The concept of Quality
- ISO 9000 role
- Quality Control Circle
- Meeting Customer's Requirements
- Achieving Quality
- The Principles governing the ISO Standard for QMS
- Quality Management System Requirements
- Steps to implement the system
- Management of Internal Audits
- Management of Data
- Review of the System
- Management Responsibility
- Resource Management
- Product realization
- Measurement, analysis and improvement
8. Kiln Process Operation (5 days)
- Process and Kiln System -Basic Principles of Operation
- Combustion Theory
- Fuel Types and Their Characteristics
- Raw Material Characteristics
- The analytical background for the chemical and physical process
- Optimization of Heat Consumption.
- Kiln Refractory
- Mass and Heat Balances
- Emission of NOx and sax from Cement Kilns
- NOx and sax in Clinker Burning Installations
- Starting and Stopping the Kiln
- Emergency Situations during Kiln Operation
- Evaluation of kiln operation
- Kiln System Process Control
§ Control Parameters
o Location of the control parameters and variables
o Preheater kiln
o Precalciner kiln
o Burning Zone Temperature (BZT)
o Pyrometer reading
o NOx of the exhaust gases
o Kiln torque
o Secondary Air Temperature. Tertiary Air Temperature
o Back End Temperature (BET)
o Oxygen control
§ Control Variables
o Fuel rate to the kiln
o Feed rate to the kiln
o Kiln draft
o Kiln speed
§ Control Strategy
o Possible kiln parameter conditions
o Decision tree
o Counteractions
§ Precalciner Control
o Calcination temperature
o Oxygen control
o Other control parameters
§ Grate Cooler Control
o Bed height and grate speed
- Control Parameters and Variables
- Actions to handling specific parameters and constraints
- Inspection Strategies for Kiln Systems
- Limits Regarding Kiln Charge
9. Kiln Process Technology (3 days)
§ Kiln Systems
§ Refractory Linings
§ Firing Systems
§ Burners and Flames
§ Combustion Engineering
§ Alternative Fuels
§ Circulation Phenomena
§ Kiln Control
§ Mass and Heat Balance
§ Main Fans
§ Process and Equipment Modification
§ Kiln System Audit
10. Coal Mill Operation (3 days)
§ Design of Process, Machinery and Basic Principles of Operation
§ Mechanical Features of the Mill
§ Drying and Grinding of Coal
§ Coal Mill Department Layout
§ Mill Components
§ Operation of the Vertical Mill
§ Methods for safe operation and handling of coal
§ Start-up, shut-down and trouble-shooting
§ Coal Grinding Mill with Inert Drying Air
11. Basic Principles of Sampling Methods and Equipment (3 days)
§ Introduction
§ Sampling Regime
o Basic considerations
o Guidelines for sample size and sampling frequency
§ Sampling of Stationary Materials
o Field sampling
o Sampling of bulk cement
§ Sampling of Conveyed Material
o Various possibilities of collecting a transverse sample
o Deviations from the ideal case
o Rules for the sampler
o Recapitulation of sampling rules
§ Critical Analysis of The Best Known Samplers
o Apparatus for transverse sampling with linear movement
o Equipment for Transverse Sampling with a Rotary Motion
o Equipment for Longitudinal Samples
o Equipment for Quasi-Point Samples
o Experimental Assessment of Samplers
§ Implement and Adequate Sampling Methods
§ Reliability of Test Result
12. Refractory (3 days)
§ General Introduction
§ Classification of Refractory Products
§ Manufacture of Refractory Products
§ Testing of Unused Refractory
§ Zoning of Cement Kilns
§ Wear of Kiln Refractory
§ Chemical Reactions Producing Refractory Damage
§ Coating Properties and Behavior
§ Influencing Parameters
13. Raw Mill Systems (4 days)
§ Purpose of Raw Grinding
§ Raw Material Properties and Product Quality
§ Basic Raw Grinding Equipment
o Available Raw Grinding Equipment
o Selection Criteria for Raw Grinding Equipment
§ Drying
o Heat Sources
o Drying Possibilities
o Drying Performance
§ Raw Grinding System
o Raw Grinding System with End-Discharge Mill
o Raw Grinding System with Center Discharge Mill
o Raw Grinding System with Air Swept Mill
o Raw Grinding System with Vertical Roller Mill
o Raw Grinding System with Roller Press
§ Comparison
o Performance
o Energy Consumption
o Grinding Installation
14. Ball Mill Operation (Raw Mill or Cement Mill) (3 days)
§ Design of Ball Mills and Basic Principles of Operation
§ Mass and Heat Balances
§ Grinding of Raw Materials
§ Drying and Grinding of Coal
§ Cement Grinding
§ Ball Mill Operation
§ Performance Testing of Ball Mill
§ Optimization of Mill Grinding Systems
§ Aspects and parameters in ball mill operation
§ Evaluation of ball mill operation
§ Responses to parameter variations during operation
§ Manipulation and parameter variation
15. Operation of Vertical Mill (3 days)
§ Design of Vertical Mills and Basic Principles of Operation
§ Mass and Heat Balances
§ Grinding of Raw Materials
§ Drying and Grinding of Coal
§ Roller Mill Operation
§ Mill operation and parameters
§ Obtain optimal results from various given inputs and constraints
§ Supervise mill operation
§ Operate the mill system within inputs, variables and constraints.
§ Required actions and set points plant operation.
§ Analyze disturbances in the mill operation
16. Cement Mills System (3 days)
§ Introduction
§ Grinding with Tube Mills
§ Mill Types
o Type of material being ground
o Number of chambers
§ Material transport
o Discharge point of material
o Grinding process
§ Elements of Tube Mills
§ External Elements
o Feed arrangements
o Discharge
o Mill shell
o Mill heads
o Mill bearings
o Mill drives
§ Internal Elements
o Overview
o Head liners
o Shell liners
o Intermediate diaphragm
o Discharge diaphragm
o Grinding media
§ Mill Control
o Optimal mill load
o Adjustment possibilities
o Process parameters
o Handling parameters
§ Mill Operating Performance
o Mill efficiency
o Separator efficiency
o Mill ventilation, heating and cooling
§ Grinding aids (GA)
§ Grinding media charges
o Grinding media charge compositions
§ Grinding media sizes
o Ball charge calculation
o Replenishment of ball charges
o Ball charge management
17. Cement Grinding Technology (3 days)
§ Overview grinding systems
§ Requirements
§ Grinding systems
§ Tube Mill Systems
o Tube Mill in Open Circuit
o Tube Mill in Closed Circuit
§ Tube Mill Systems with Pregrinding Unit
o Roller Press
o Vertical Shaft Impact Crusher
o Vertical Roller Mill
§ Finish Grinding Systems
o Roller Press
o Vertical Roller Mill
o Horizontal Roller Mill
§ Comparison
18. Plant Audit (3 days)
§ Philosophy of Plant Audit
§ Energy
§ Main Equipment of Cement Plant
§ Conveying and Storage
§ Electrical Equipment
§ Pump, Blower, Compressor
§ Raw Mill System Audit
§ Kiln System Audit
§ Cement Mill System Audit
19. Crusher Operation (3 days)
§ Manuals Operation
§ Access and Lifting Gear
§ Cleanliness
§ Oil Analysis
§ Operation and Maintenance Log
§ Safety
§ Minor Maintenance
20.
Quality
Assurance (3 days)
§ Introduction
§ Definition of Quality
§ Objectives of QA
§ Activities of QA
o Quality Planning
o Quality Control
o Quality Audit
§ QA system
o The Elements of a Quality Assurance System
o Organization of Quality Assurance
o Quality Assurance Handbook
§ Quality Cost
o Introduction
o Elements of Quality Costs
o Relationship of Quality Costs to Sales
21. Cement Quality (3 days)
§ Chemical analyses of raw meal and other materials
§ Calculation of the raw mix composition and sampling methods
§ Composition of raw mix and clinker characteristics
§ Methods for evaluation of cement quality
§ Chemical changes in cement during grinding and storage
§ Blended Cement
§ Cement Grinding
§ Portland Cement and Concrete Technology
§ X-Ray Analysis
§ Sampling and Sample Preparation from Crushing and Grinding
§ Burnability of Raw Mix
§ Quality Control; Laboratory
§ Grindability of Clinker
§ Influence of Manufacturing Parameters on Clinker
22. Quality Control: Concept, Control Plan, Procedures (3 days)
§ Introduction
§ Quality Control Concept
§ Control Plan
§ Control Parameters
o Supplied Materials
o Quarry
o Pre-blending
o Raw Meal
o Kiln Feed
o Hot meal
o Clinker
o Ground Cement
o Dispatched Cement
o Ground Coal
§ Uniformity
§ Sampling, Preparation and Testing
§ Quality and Testing Standard (ASTM, SNI, JIS etc.)
§ QCX/Proportioner or QCX/Blend Expert
§ Introduction Microscopy
23. Raw Mix Design (3 days)
§ General
§ Definition of Criteria for Mix Calculation
§ Principles and Methods of Mix Proportioning
o X-Ray Pattern
o Manual Calculation
o Graphical Methods
o Programmable Calculator
o Computer Optimization
§ Raw Mix Assessment
o Mix Type
o Comparison of Raw Mix with Standard Specifications
o Mineralogical Composition of Cement Raw Mixes.
o Raw Mixes with regard to Cement Production
o Evaluation of Laboratory Test Results
§ QCX/Proportioner or QCX/Blend Expert
24. Laboratory (3 days)
§ Sample and Preparation
o Methods
o Application
o Time of Preparation
o Maintenance of Sampling Equipments
o Suppliers
§ Laboratory Equipment
§ Gravimetri
§ Titration of Carbonates
§ Complexometric Titration
§ Blaine
§ Determination of Sulphur and Carbon Dioxide
§ Atomic Emission Spectrometry
§ X-Ray Fluorecence
§ X-RAY Diffraction
§ Microscopy
§ Thermal Shock Testing of Basic Refractories
§ Differential Thermal Analysis (DTA)
§ Thermo Gravimetric Analysis(TGA)
§ Maintenance of Testing Equipments
§ Standards understanding and application
o ASTM
o JIS
o British standards
o Singapore standards
o Australian standards