PRODUCTION SECTION

Training Course Syllabus

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
• 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
• 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

2.   Cement Manufacturing Course Level 1 (3 days)

3.   Cement Manufacturing Course Level 2 (5 days)

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
  • Power on/off procedure
  • Lock out procedure
  • Starting procedure
  • Mechanical Safety
    • Materials and equipment lifting procedure
    • Welding safety
    • Tools machining safety procedures
    • Fire Extinguisher
    • Hazard Identification & Risk Assessment
    • Lock off procedures
    • Equipment entry procedures
    • Handling flammable materials
    • Safety Induction Development
    • Personal Protective Equipment (PPE)
      • Usage Procedure and Monitoring
      • Safety Inspections on
        • Construction Equipment
        • Chemicals
        • Heavy equipment mobile plant safety
        • Drilling and blasting safety
        • Hazard Identification & Risk Assessment                   
        • Work permit system                                                                            
          • Convince space                                    
          • Hot work Lock Out Tag Out (LOTO)                           
          • Scaffolding
          • 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
• Location of the control parameters and variables
• Preheater kiln
• Precalciner kiln
• Burning Zone Temperature (BZT)
• Pyrometer reading
• NOx of the exhaust gases
• Kiln torque
• Secondary Air Temperature.  Tertiary Air Temperature
• Back End Temperature (BET)
• Oxygen control
• Control Variables
• Fuel rate to the kiln
• Feed rate to the kiln
• Kiln draft
• Kiln speed

• Control Strategy
  • Possible kiln parameter conditions
  • Decision tree
  • Counteractions

• Precalciner Control
  • Calcination temperature
  • Oxygen control
  • Other control parameters

 

• Grate Cooler Control
• 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
• Basic considerations
• Guidelines for sample size and sampling frequency
• Sampling of Stationary Materials
• Field sampling
• Sampling of bulk cement
• Sampling of Conveyed Material
• Various possibilities of collecting a transverse sample
• Deviations from the ideal case
• Rules for the sampler
• Recapitulation of sampling rules
• Critical Analysis of The Best Known Samplers
  • Apparatus for transverse sampling with linear movement
  • Equipment for Transverse Sampling with a Rotary Motion
  • Equipment for Longitudinal Samples
  • Equipment for Quasi-Point Samples
  • 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
  • Available Raw Grinding Equipment
  • Selection Criteria for Raw Grinding Equipment
  • Drying
    • Heat Sources
    • Drying Possibilities
    • Drying Performance
    • Raw Grinding System
      • Raw Grinding System with End-Discharge Mill
      • Raw Grinding System with Center Discharge Mill
      • Raw Grinding System with Air Swept Mill
      • Raw Grinding System with Vertical Roller Mill
      • Raw Grinding System with Roller Press
      • Comparison
        •  Performance
        •  Energy Consumption
        •  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
• Type of material being ground
• Number of chambers
• Material transport
  • Discharge point of material
  • Grinding process
  • Elements of Tube Mills
  • External Elements
  • Feed arrangements
  • Discharge
  • Mill shell
  • Mill heads
  • Mill bearings
  • Mill drives
  • Internal Elements
  • Overview
  • Head liners
  • Shell liners
  • Intermediate diaphragm
  • Discharge diaphragm
  • Grinding media
  • Mill Control
  • Optimal mill load
  • Adjustment possibilities
  • Process parameters
  • Handling parameters
  • Mill Operating Performance
  • Mill efficiency
  • Separator efficiency
  • Mill ventilation, heating and cooling
  • Grinding aids (GA)
  • Grinding media charges
  • Grinding media charge compositions
  • Grinding media sizes
  • Ball charge calculation
  • Replenishment of ball charges
  • Ball charge management

 

17.       Cement Grinding Technology (3 days)

•  Overview grinding systems
• Requirements
• Grinding systems
• Tube Mill Systems
• Tube Mill in Open Circuit
• Tube Mill in Closed Circuit
• Tube Mill Systems with Pregrinding Unit
• Roller Press
• Vertical Shaft Impact Crusher
• Vertical Roller Mill
• Finish Grinding Systems
• Roller Press
• Vertical Roller Mill
• 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
  • Quality Planning
  • Quality Control
  • Quality Audit
  • QA system
    • The Elements of a Quality Assurance System
    • Organization of Quality Assurance
    • Quality Assurance Handbook
    • Quality Cost
      • Introduction
      • Elements of Quality Costs
      • 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
  • Supplied Materials
  • Quarry
  • Pre-blending
  • Raw Meal
  • Kiln Feed
  • Hot meal
  • Clinker
  • Ground Cement
  • Dispatched Cement
  • 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
• X-Ray Pattern
• Manual Calculation
• Graphical Methods
• Programmable Calculator
• Computer Optimization
  • Raw Mix Assessment
  • Mix Type
  • Comparison of Raw Mix with Standard Specifications
  • Mineralogical Composition of Cement Raw Mixes.
  • Raw Mixes with regard to Cement Production
  • Evaluation of Laboratory Test Results
    • QCX/Proportioner or QCX/Blend Expert

 

24.       Laboratory (3 days)

• Sample and Preparation
  • Methods
  • Application
  • Time of Preparation
  • Maintenance of Sampling Equipments
  • 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
    • ASTM
    • JIS
    • British standards
    • Singapore standards
    • Australian standards