Course

Cement Kiln Pyroprocessing Course

This 6 week course will provide 24 lectures on different topics associated with pyroprocessing in cement kilns. There will also be exercises and quizzes to assist with the learning process and exams at the end of weeks 1 to 5.

Course Content

The course complements and extends the coverage of cement manufacturing technology course provided by CemNet Training. It is a natural partner to the Grinding and Milling course providing details of the processing equipment of cement kiln systems in the same way as the grinding and milling course does for milling systems. Topics covered will include:

- Feeding systems
- Preheaters
- Process Fans
- Precalciners
- Alkali Bypasses
- Rotary Kilns
- Coolers
- Safety and Process Control of Cement Kilns

Course Material

Throughout the course the lectures are supplemented with exercises allowing participants to relate the course material to their cement factories, or the cement factories of their clients in the case of equipment or service suppliers to the cement industry. Certification is achieved by completing a satisfactory level of exercises, and by end of module exams.

The course is complete with downloadable handouts of the lectures, exercises, and reading material for the training record.

Content Breakdown

Module 1:

On completion of this module, you will understand:

The way the course is organised and how the mass and energy balance of a cement kiln provides the structure for the course
The importance of accurate dosing of feed and solid fuels to a cement kiln and the technology used to ensure this
The basis for the difference between the kiln feed to clinker factor and the stoichiometric raw mix factor and the importance of the dust losses from a cement kiln

This understanding will be enhanced and made relevant by participants completing exercises evaluating and describing the context, equipment, layout and resources provided on their own cement factories.

Lecture 1 - Course Introduction
Exercise 1
Lecture 2 - Kiln Feeding Systems
Exercise 2
Lecture 3 - Fuel Dosing Systems
Exercise 3
Lecture 4 - Dust Losses
Exercise 4
End of Module 1 exam

Module 2:

On completion of this module, you will understand:

The technology of the preheater-induced draft fan, the biggest consumer of electricity in the kiln system
The problems induced draft fans can suffer with build-up on the impellors and the possible solutions
The detail of suspension preheaters and how they impact the induced draft fan
The alkali cycle and the solutions that can be applied, including alkali bypasses

Lecture 5 - Induced Draft Fans
Exercise 5
Lecture 6 - Preheater Fan Build-Up
Exercise 6
Lecture 7 - Suspension Preheaters
Exercise 7
Lecture 8 - Alkali Cycles & Bypasses
Exercise 8
End of Module 2 exam

Module 3

In this module, you will learn about:

Precalciners in their different configurations and their implications for the operation of a cement kiln
The special considerations involved in firing a cement kiln with natural gas and heavy fuel oil
The increasingly important topic of burning alternative fuels in a cement kiln

Lecture 9 - Precalciners
Exercise 9
Lecture 10 - Gas Firing
Exercise 10
Lecture 11 - Fuel Oil Firing
Exercise 11
Lecture 12 - Alternative Fuels
Exercise 12
End of Module 3 exam

Module 4

We have reached the rotary section of the kiln where the process is most intense and also our pyroprocessing course is at its most intense. In this module you will learn about:

The rotary section of the kiln, how its mechanical integrity must be preserved during operation and the radiation and convection losses from the kiln shell
The kiln main burner and the requirements for efficient combustion of the fuel in the kiln
The combustion product gases from burning the fuel in the kiln and how the volume of exhaust from the kiln is estimated
Coolers of different designs and generations and how cooler efficiency is defined

Lecture 13 - Rotary Kilns
Exercise 13
Lecture 14 - Main Burner
Exercise 14
Lecture 15 - Combustion Gas & Oxygen
Exercise 15
Lecture 16 - Clinker Coolers
Exercise 16
End of Module 4 Exam

Module 5

We have now considered each part of a cement kiln system in isolation and must now turn out attention to the system wide factors that must be taken into consideration. In this module you will learn about:

We will start by reviewing the overall mass and energy balance of a cement kiln and what is the maximum thermal energy efficiency that can be achieved
We then consider the important considerations and procedures for starting-up the kiln
Operation and control of a cement kiln presents certain challenges to the kiln operator and these will be reviewed
We then complete this week's sessions with a review of the important safety factors involved in operating a cement kiln

Lecture 17 - Mass and Energy Balance
Exercise 17
Lecture 18 - Start-Up
Exercise 18
Lecture 19 - Operation and Control
Exercise 19
Lecture 20 - Safety
Exercise 20
End of Module 5 exam

Module 6

In this final week of the course, we turn our attention to emergent issues and technologies for pyroprocessing in cement kilns.

Emissions from cement kilns are under growing scrutiny throughout the world therefore we consider the technology that is deployed with cement kiln systems to mitigate emissions
Cement manufacture is an energy-intensive industry, and energy costs are continuously rising therefore, we consider the opportunities for waste heat power generation
The world's people and governments are increasingly determined to reduce global CO2 emissions, and the cement industry will have to make its contribution therefore, we consider the technology options for carbon capture from cement kilns
Finally, we look forward to the next 40 years and the changes which the cement industry and cement kilns will have to undergo if targets for CO2 emission reductions are to be achieved

Lecture 21 - Emissions Mitigation
Exercise 21
Lecture 22 - Waste Heat Power Generation
Exercise 22
Lecture 23 - Lowering CO2 and Carbon Capture
Exercise 23
Lecture 24 - Future of Pyroprocessing