Course 

Cement Kiln Refractories

Principal refractory performance issues in the rotary kiln, refractory materials, process efficiency of linings, inspection, repair and maintenance, optimised refractory usage. A total course for cement production staff who, until now, have only been able to 'learn on the job'.

Course Content

  • Overview of refractory materials
  • Refractories for the rotary kiln
  • Principal refractory performance issues in the rotary kiln
  • Inspection, condition monitoring, repair and maintenance of the rotary kiln lining
  • Refractories for the static plant
  • Main performance issues and problems in the static plant
  • Inspection and condition monitoring of static plant linings
  • The refractory lining and its contribution to process efficiency
  • Future challenges

Course Material

The Cement Kiln Refractories e-Learning course is intended to fill a gap in the cement industry where no formal training in refractories is generally available. Engineers will no longer be obliged to gain their refractories experience 'on the job', with the inevitable consequence of perpetuating mistakes.

This certified training will provide the accumulated experience of more than 30 years in cement kiln refractory engineering, and will allow informed decisions to be made regarding selection, installation and maintenance of refractories and refractory systems.

The course begins with the key principals of refractory materials for cement kilns, covering selection, installation and maintenance for all sections of the kiln. Inspection, condition monitoring, preventative and planned maintenance are all covered and also cement kiln refractory performance benchmarking and the development of refractory improvement plans.

Important relationships between the refractory lining and process efficiency will be discussed in some detail.

On completion of this course, delegates should have a firm appreciation of the importance of the many refractory choices to be made in both the rotary kiln and static plant areas such as preheaters, precalciners, kiln hoods and coolers.

Successful participants will qualify for certification of completion and will be much better placed to contribute to improvement plans within their factories and production lines.

Lecture breakdown:


Module 1 - Refractory Technology
On completion of this module, you will understand:
  1. The different types of refractories and how they are manufactured
  2. The way the properties of those refractories determine the appropriate service conditions for the use of those refractories.
  3. The types of refractories that are used in the different sections and zones of cement kilns and why those refractories are suitable for the service conditions in those sections and zones.
  4. You will also have begun to collect the data required to relate the course material to your cement kiln(s), or those of your clients.
  • Lecture 1 – Introduction
  • Lecture 1.2 - Refractories Introduction
  • Lecture 1.3 - Refractories Manufacture
  • Exercise 1.3
  • Lecture 1.3 Quiz
  • Lecture 1.4 - Insulating & Monolithic RefractoriesFile
  • Lecture 1.5 - Refractory Data Sheets
  • Exercise 1.5
  • Lecture 1.6 - Cement Kilns
  • Lecture 1.6 Quiz
 
Module 2 - Rotary Kiln Refractory Technology
On completion of this module you will understand:
  1. The reasons why a lining constructed of individual tapered bricks is ideally suited to lining a cement kiln
  2. The way the lining of the kiln is split into zones and the types of refractories used to line those zones
  3. How to install the lining in a rotary cement kiln
  4. How to bring the lining into service and achieve the maximum possible life from the lining in service
  5. The possible failure modes of the lining and how to minimise or reduce the likelihood of those failures occurring
  6. The requirements for inspection, demolition and repair of the lining when that inevitably becomes necessary
  7. Exercises will allow you to develop software tools to apply the course material to the lining of the rotary section of your kilns.
  • Lecture 2.1 - Rotary cement kiln linings File
  • Exercise 2.1
  • Lecture 2.2 - Cement Kiln Zoning File
  • Exercise 2.2
  • Lecture 2.3 - Brick lining installation File
  • Exercise 2.3
  • Lecture 2.4 - Heating Up File
  • Exercise 2.4
  • Lecture 2.5 - Lining in Service File
  • Exercise 2.5
  • Lecture 2.6 - Failure Modes File
  • Lecture 2.7 - Inspection, Demolition & Repair File
  • Exercise 2.7
  • Module 2 – Quiz
 
Module 3 - Static Plant Refractory Technology
 
On completion of this module you will understand:
 
  1. Why the static plant areas have become the focus of many of the refractory performance issues associated with modern, high capacity cement kilns.
  2. The function of the static plant lining and how that can be achieved by different lining designs.
  3. The installation of static plant linings.
  4. Bringing the static plant lining into service.
  5. Failure modes of the static plant lining.
  6. The issues associated with the inspection, demolition and repair of static plant cement kiln linings.
  7. Exercises will allow you to develop software tools to apply the course material to the lining of the static sections of your kilns.
 
  • Lecture 3.1 - Static lining principles File
  • Exercise 3.1
  • Lecture 3.2 - Static plant evolution File
  • Exercise 3.2
  • Lecture 3.3 - Installation of static linings File
  • Exercise 3.3
  • Lecture 3.4 - Light-Up File
  • Exercise 3.4
  • Lecture 3.5 - In Service File
  • Exercise 3.5
  • Lecture 3.6 - Inspection & Repair File
  • Exercise 3.6
 
Module 4 - Cement Kiln Refractory Performance Improvement
 
On completion of this module you will understand:
 
  1. The requirements for the continual improvement of cement kiln refractory lining performance.
  2. The importance of detailed and accurate record keeping for all aspects of refractory installation, life in service and repair.
  3. How to benchmark refractory performance, installation and repair and compare your performance with best practice elsewhere in the world.
  4. How to develop a continuous refractory performance improvement plan.
  5. Exercises will allow you to document the history of refractory performance in your cement kilns, compare that performance with other similar kilns, identify areas where performance can be improved, and develop plans to realise those improvements.
 
  • Lecture 4.1 - Continuous Performance Improvement File
  • Lecture 4.2 - Benchmarking