خطة التدريب لهذا العام

Training objectives:

This one-week course equips cement kiln operators with the skills to effectively operate a kiln using the KHD simulator. Participants will gain a deeper understanding of key process parameters and how they impact clinker quality and production efficiency. Additionally, they will develop proficiency in handling various operational scenarios and troubleshooting potential kiln issues.

Who Should Attend:

 Cement kiln operators with basic knowledge of cement production processes.

This intensive one-week course equips operators with the skills to operate a cement kiln effectively using the KHD simulator.

Training Outline:

Day 1:  Master the KHD simulator, Get hands-on with the simulator interface and controls.

Day 2: Understand raw materials and feeding systems, learn preheater operation (simulator), explore how raw material variations impact the kiln (exercises), and practice responding to related issues in a simulated scenario.

Day 3: Deep dive into kiln anatomy and burning zone dynamics (theory), explore fuel selection and combustion processes, learn to monitor and control key kiln parameters (simulator), optimize burning zone conditions (scenario-based training), and gain knowledge about clinker quality control.

Day 4: Understand clinker cooler operation and heat recovery (theory), practice product quality control procedures (simulator), troubleshoot clinker cooler issues (simulated scenario), and get introduced to kiln emission control systems.

Day 5: Learn advanced control strategies for efficient and stable kiln operation, explore fuel blending and alternative fuels, practice process optimization techniques (simulator), and respond to major kiln upsets through scenario-based training.

Training objectives:

This course aims to equip participants with a comprehensive understanding of cement kiln operations, enabling them to optimize kiln performance, minimize downtime, and ensure efficient and sustainable cement production. Participants will gain knowledge in areas such as raw material quality, fuel combustion, clinker formation, emission control, and kiln management techniques.

Target audience:

This program is designed for operators, shift leaders, and area managers.

Course outlines:

• understand the fundamentals of cement kiln operations:
• Explain the basic principles of cement production.
• Describe the various stages of the cement manufacturing process.
• Analyze the impact of kiln feed on kiln performance:
• Assess the importance of raw material quality and composition.
• Optimize fuel combustion in the cement kiln:
• Explain the combustion process and its impact on energy efficiency.
• Identify common fuel types and their characteristics.
• Analyze the factors affecting flame temperature and heat transfer.
• Manage sulfur, alkali, and chlorine in the cement kiln:
• Understand the sources and effects of sulfur, alkali, and chlorine compounds.
• Discuss techniques for controlling these compounds and minimizing their impact on clinker quality and kiln performance.
• Prevent and troubleshoot kiln shutdowns:
• Identify common causes of kiln shutdowns.
• Develop strategies for preventing and minimizing downtime.
• Implement effective troubleshooting techniques to resolve kiln issues.
• Acquire the skills of a successful kiln manager:
• Develop effective leadership and communication skills.
• Make informed decisions based on data analysis and technical expertise.
• Implement continuous improvement initiatives to optimize kiln performance.

Training objectives:

To equip participants with the knowledge and skills necessary to effectively plan, execute, and manage maintenance shutdowns in the cement industry, maximizing efficiency, safety, and cost-effectiveness.

Target audience:

The program targets the planning and scheduling mechanical, electrical maintenance and production engineers.

Course outlines:

1. Introduction to Maintenance Strategies & Planning

• Maintenance Strategies & Basic Definitions

• Planning vs. Scheduling

• Definitions and types of shutdowns (Major, Minor, Routine, Emergency)

• Importance & Benefits of effective shutdown planning (cost savings, increased equipment lifespan, improved safety)

2. Pre-Shutdown Planning and Preparation

• Pre-shutdown assessment

• Strategic Shutdown Planning (Scope definition, Stakeholder identification & Team Building)

• Logistics and materials management

• Detailed Shutdown Planning & Scheduling

• Risk & Safety Management

3. Shutdown Execution and Coordination

• Execution Best Practices

• On-the-Ground Coordination

4. Post-Shutdown Activities and Recovery

• Equipment start-up and performance verification

• Cleaning and housekeeping

• Documentation and lessons learned analysis

• Maintenance history updates and future planning

• Performance evaluation and continuous improvement strategies

• Chemical and Mineralogical composition.
• Chemical composition.
• Mineralogical composition –major constituents
• Properties of major constituent
• Minor constituents
• Potential compound composition by the Bogue method
• Setting and Hardening
• Hydration of cement
• Development of structure in cement paste
• Factors affecting the rate of hydration
• Strength of the hardened paste
• Factors affecting strength
• Effect of cement composition and fineness on its properties
• The major constituents
• The minor constituents
• Effect of specific area

• Introduction to Refractories
• Definition and properties of refractories
• Types of refractories used in cement kilns (fireclay, high alumina, magnesia, etc.)
• Factors affecting refractory selection (temperature, chemical attack, mechanical wear, etc.)
• Refractory Design and Construction for Cement Kilns
• Kiln anatomy and refractory zoning
• Design considerations for different kiln zones (burner zone, transition zone, burning zone, cooling zone)
• Quality control and inspection procedures
• Refractory Maintenance and Troubleshooting
• Common refractory failure mechanisms (spalling, cracking, erosion)
• Predictive maintenance techniques (visual inspection, thermography)
• Repair and patching procedures
• Refractory linings for alternative fuels.
• Castable refractories.

• Day 1: Mill Ventilation & False Air Effects (Ball Mill)
• Importance of proper ventilation and false air control in ball mills
• Airflow measurement techniques 
• Day 2: Separation Efficiency & Product Fineness (Ball Mill)
• Principles of separation efficiency
• Methods for optimizing separator operation
• Day 3: Ball Charge Calculation & Optimization (Ball Mill)
• Grinding media distribution and its effect on mill performance
• Wear rate analysis and media replacement strategies
• Practical exercises on ball charge calculations
• Day 4: Grinding Efficiency & Wear Patterns (Vertical Mill)
• Relationship between grinding efficiency and dam ring adjustment
• Effect of table and roller wear on grinding performance
• Day 5: Mill Ventilation, False Air, & Process Optimization (Vertical Mill)
• Importance of proper mill ventilation in vertical mills
• Measuring airflow and identifying false air sources
• Case studies, troubleshooting, and practical exercises

• Mapping introduction
• Map Basics
• Map Components
• Types of map scales
• Quarrying topographic maps.
• Quarrying geologic maps.
• Quarrying geologic structures.
• Folding Structures 
• Faulting Structures 
• Unconformity Structures 
• Software applications for different maps 
• Surfer program
• Map Source Program
• GPS Global Positioning system lab and application
• Google Earth

Training objectives:

Equip participants with the knowledge and skills to effectively maintain, troubleshoot, and optimize low and medium voltage (LV/MV) motors in a cement plant environment, achieving reliable operation, energy efficiency, and improved power factor.

Target audience:

This program addresses the Mid-level electrical engineers

Course outlines:

1.      LV/MV Motor Maintenance:

·         Understand the principles and operation of different types of LV/MV motors used in cement plants (induction, synchronous, DC).

·         Perform routine inspections and preventive maintenance procedures for LV/MV motors, including lubrication, vibration analysis, bearing checks, and winding insulation tests.

2.      Measurements and Diagnostics:

·         Interpret key motor measurements (current, voltage, power, power factor, speed) using instruments like multi-meters, clamp meters, and power analyzers.

·         Analyze motor performance data to identify potential problems and track maintenance needs.

3.      Slip Ring Motor Maintenance:

·         Gain in-depth knowledge about the operation and maintenance of slip ring motors used in cement plants.

·         Understand and adjust slip ring settings to optimize motor performance and efficiency.

4.      Energy Consumption and Power Factor:

·         Analyze factors affecting motor energy consumption and power factor.

·         Implement strategies for improving motor efficiency.

Training objectives:

Equip participants with the knowledge, skills, and practical experience required to effectively maintain and troubleshoot the mechanical elements of crucial cement production equipment, including the kiln, cooler, ball mill, and vertical mill.

• Gain in-depth understanding of the design, function, and operating principles of each equipment type.
• Identify and analyze common mechanical failures.
•  Develop proficiency in preventative and corrective maintenance procedures for each equipment

Target audience:

This course addresses Mechanical engineers working in maintenance, preparation office, Inspection and preventive maintenance, this course is equally suitable for production operatives involved in maintenance activities.

Course outlines:

1.      Kiln system main components

·         Kiln shell.

·         Thrust roller

·         Seals

·         Girth gear and pinion

·         Support stations

2.      Cooler mechanical parts and maintenance.

3.      VRM mechanical parts and maintenance.

4.      Tube mill maintenance.

5.      Utilities systems.

6.      Welding techniques.

7.      Open discussion.

Training objectives:

Upon completion of this course, participants will be able to:

• Identify and describe the key components of a hydraulic circuits.
• Analyze and interpret hydraulic schematics.
• Apply hydraulic principles to solve practical problems in the cement industry: This involves understanding how hydraulics powers equipment like crushers, stackers, reclaimers, roller mills, rotary kilns, and coolers. 
•  Safely operate and maintain hydraulic systems.

Target audience:

This program tackles the essential principles and techniques employed by Maintenance, inspection and preparation mechanical engineers.

Course outlines:

1.      Component of Hydraulic Circuit

·         Hydraulic pumps

-       Gear pump

-       Vane pump

-       Screw pump

-       Axial piston pump

-       Radial piston pump

·         Hydraulic valves

-       Non return valves

-       Directional control valves

-       Pressure control valves

-       Flow control valves

·         Hydraulic cylinders

·         Accumulators

·         Cartridge "logic' valves

2.      Hydraulic applications in Cement Industry

·         Roller Mills

·         Rotary Kilns

·          Coolers

Training Objectives:

This course aims to equip participants with the critical knowledge and practical skills necessary to ensure consistent, high-quality cement production within the framework of international standards. Through a comprehensive exploration of quality assurance principles, raw material control, clinker optimization, and standard compliance

Target audience:

Stay ahead of the curve in the ever-evolving quality landscape with this program designed for mid-level engineers adapting to new technologies and standards.

Course Outlines:

1.         Definition of Quality in Cement Industry

2.         Activities in Quality Assurance

3.         Raw mix design calculations

4.         Quality of Raw Materials

·         Grindability

·         Fineness

·         Moisture

·         Granulometry of mill feed

5.         Quality of clinker

·         Energy consumption

·         Burning behavior

·         Materials related to operational problems

·         Clinker quality

6. Quality of Cement:

· Effect of clinker quality on the properties of cement

· Factors influencing grind ability of Cement

· Effect of grinding on the cement properties

· Gypsum during cement grinding

7. Cement standards:

·  ASTM

·  B.S.

·  EN

Training objectives:

Train participants to identify and resolve kiln operation issues affecting clinker quality and production KPIs. Focus on the impact of raw materials, operational techniques, false air, bypass ratio, and cyclone efficiency on kiln performance. Provide practical examples and troubleshooting exercises to enhance problem-solving skills.

Who Should Attend:

  Kiln operators, shift leaders and process engineers in cement industry.

Training Outline:

Day 1: Raw Materials & Their Effect on Clinker Quality

• Influence of raw material chemistry and burnability on clinker composition.
• Troubleshooting raw material-related issues affecting clinker quality.

Day 2: Raw Materials & Their Effect on Kiln Performance

• Impact of raw mix variations on kiln stability, coating formation, and fuel consumption.
• Practical analysis of raw material adjustments to optimize kiln performance.

Day 3: Kiln Operation Techniques & Their Effect on KPIs

• Relationship between kiln control strategies and production efficiency.
• Troubleshooting operational issues affecting kiln availability and fuel efficiency.

Day 4: False Air, Bypass Ratio & Cyclone Efficiency

• Effect of false air and bypass ratio on heat consumption and kiln stability.
• Practical evaluation of cyclone performance and its impact on dust losses and efficiency.

Day 5: Practical Troubleshooting & Case Studies

• Identifying and resolving common kiln issues through real-world case studies.
• Hands-on troubleshooting exercises based on actual kiln performance data.

Training objectives:

Train participants on the proper operation of ball mills and vertical mills using the KHD simulator to maximize production while minimizing electrical energy consumption. Focus on optimizing mill performance under different raw material conditions, troubleshooting operational issues, and applying real-time adjustments using the simulator.

Who Should Attend:

  Mill operators in cement industry.

Training Outline:

Day 1: Ball Mill Operation & Process Control

• Key process parameters affecting ball mill performance and energy efficiency.
• Simulator training on setting optimal operating conditions for maximum output.

Day 2: Raw Material Variations & Ball Mill Performance

• Impact of raw material properties on grinding efficiency.
• Simulator practice on adjusting mill parameters for different raw material conditions.

Day 3: Troubleshooting & Optimization in Ball Mills

• Simulator-based troubleshooting and adjustments to improve performance.

Day 4: Vertical Mill Operation & Process Optimization

• Key operating principles, including dam ring height, grinding pressure, and wear patterns.
• Simulator training on optimizing mill settings for stable and efficient operation.

Day 5: Troubleshooting & Raw Material Impact in Vertical Mills

• Effect of raw material variations on mill performance and process stability.
• Simulator practice on detecting and resolving common vertical mill issues.

Training objectives:

Equip participants with in-depth knowledge of pollution control systems, focusing on baghouses and electrostatic precipitators (ESPs) from mechanical and operational perspectives. Train participants in spark analysis for ESPs and carbon footprint calculations in clinker production. Enhance skills to optimize emissions control and environmental compliance.

Who Should Attend:

  Operators, shift leaders and area managers of kiln

Training Outline:

Day 1: Preheater Mechanical Components & Daily Checks

• Main mechanical components of the preheater (cyclones, dip tubes, riser ducts, meal pipes).
• First-level inspection and daily checks

Day 2: Kiln Mechanical Components & Alignment Basics

• Key kiln components (shell, tyres, rollers, girth gear, seals, drive system).
• First-level inspection techniques,

Day 3: Cooler Mechanical Components & Maintenance

• Main cooler parts (grates, fans, clinker crusher).
• Daily checks for wear, airflow efficiency, and clinker bed stability.

Day 4: Kiln System Lubrication & Common Mechanical Failures

• Lubrication requirements for kiln components, bearings, and gear systems.
• Identifying and addressing common failures (hot bearings, misalignment, excessive wear).

Day 5: Inspection Techniques & Troubleshooting Case Studies

• Systematic inspection methods for detecting mechanical issues in preheater, kiln, and cooler.
• Troubleshooting real-world mechanical failures using case studies.

Training objectives:

Equip participants with in-depth knowledge of pollution control systems, focusing on baghouses and electrostatic precipitators (ESPs) from mechanical and operational perspectives. Train participants in spark analysis for ESPs and carbon footprint calculations in clinker production. Enhance skills to optimize emissions control and environmental compliance.

Who Should Attend:

  Operators, shift leaders and area managers of kiln

Training Outline:

Day 1: Baghouse Design & Mechanical Components

• Structure, components, and working principles of baghouses.
• Common mechanical failures, troubleshooting, and maintenance best practices.

Day 2: Baghouse Operation & Performance Optimization

• Effect of differential pressure, filter media selection, and cleaning systems on efficiency.
• Troubleshooting high emissions, pressure drops, and bag failures.

Day 3: Electrostatic Precipitator (ESP) Design & Operation

• ESP working principles, mechanical components, and electrode configurations.
• Impact of process parameters on ESP efficiency and emission control.

Day 4: Spark Analysis & Troubleshooting in ESPs

• Causes and effects of sparks in ESPs, detection methods, and prevention techniques.
• Troubleshooting high resistivity, rapping inefficiencies, and voltage fluctuations.

Day 5: Carbon Footprint in Clinker Production

• Sources of CO₂ emissions in clinker production and their impact on sustainability.
• Calculation methods for carbon footprint and strategies for emission reduction.

ASEC Cement Manufacturing Course "ACMC"

This Course provides for a comprehensive view of the scientific theoretical bases and practical hands-on the cement manufacturing; a strong emphasis is given to raw materials and process inter-relations.

Our Vision:

Sharing information between those who have them and those who have the need renders information more valuable on both sides, and creates active cooperation between cement professionals.

Participants:

ACMC, a four-week course, addresses engineers, chemists and geologists with few years of practical experience. It also addresses those who like to refresh up their knowledge and widen up their views. ACMC is prepared to give professionals of different specialization a wider scope of various phases of the process and keep them up to date with the state-of-the-art technology in the various fields of Cement Industry.

Duration: 4 weeks

Instructors & Methodology:

Backed with 49 years history of success in studying, constructing, and operating of more than 34 cement production lines, ASEC is an unrivaled source for cement experience, which is drawn from real life expertise. ASEC courses are instructed mainly by ASEC senior staff members and department managers in addition to a group of distinguished cement professionals & university professors.

Instructors are gifted, faithful to the mission and very well trained to use Participative learning Methodology where they act as catalysts to create a pool of sound knowledge and experience in the subject they discuss.

To enhance discussions and experience transfer, more than one instructor and expert participate in the session. Discussion groups and case studies are held to provide continuous interactions within participants to encourage exchange of experience.

Course outlines

• Raw materials for cement industry
• Raw materials studies
• Rock sampling
• Mix design and specification
• Quarrying
• Calculation of raw materials mix composition
• Comminution engineering
• Crushers
• Preblending
• Raw grinding systems
• Continuous conveying and handling systems
• Dimensioning of tube mills
• Mechanical elements of tube mills
• Mill liners and grinding media
• Vertical roller mills
• Silos & homogenization
• Cement standards testing
• Quality assurance in cement industry
• Kiln & preheater systems
• Combustion engineering
• Burners
• Clinker burning process
• Cooler systems
• Refractories
• Heat balance and heat transform
• Circulation phenomena
• Precalcining systems
• Fluid mechanics and thermodynamics
• Gas temperature and flow measurement
• Electrostatic precipitators
• Electrostatic precipitators efficiency measurement
• Gas analyzer
• Bag filters
• Mill ventilation and cement cooling
• Feed, storage and dispatch
• Problems with cement dispatch and storage
• Instrumentation & process control
• Electrical transformers
• Motors & distribution
• Cement grinding systems
• White cement
• Cement hydration
• Upgrading projects of existing plant
• Business economics
• Communication skills
• Cement plant project

Training Objectives:

This course aims to empower participants with the essential theoretical and practical skills to master X-ray fluorescence (XRF) analysis techniques. Through a comprehensive exploration of sample preparation methods for solids, powders, and liquids, error identification and mitigation strategies, and foundational knowledge of XRF instrumentation

Target audience:

Elevate your quality engineering expertise to the next level with this program tailored for mid-career practitioners.

Course Outlines: 

1.      Analysis principle

• X-ray emission
• Photoelectric absorption

2.      Instrumentation

• Types of X-Ray
• X-ray tube
• Type of WDX instrumental

-       Sequential instrumentals

-       Simultaneous instrumentals

• Instrumental components

-       Goniometer

-       Collimators

-       Crystals

-       Detectors

3. Sample preparation

• sample preparation for Solids
• sample preparation for powders

-       Briquet method

-       Fusion technique

• sample preparation for liquids

4. Errors in X-Ray Analysis

• Types of error in X-Ray analysis
• Errors during sample preparation
• Errors during XRF measurements 

Training objectives:

This intensive course empowering participants to master all stages – from selecting the optimal kiln system based on raw materials and fuel options to navigating the complexities of preheater operation, efficient clinker cooling, and optimizing performance through air, mass, and heat balance calculations.

Target audience:

The program addresses the process engineer and plant operators.

Course outlines:

1.      Introduction to the Pyro Process

·         Overview of the cement production process.

·         Different kiln systems and their characteristics.

2.      Fuel and combustion: Understanding different fuel types (coal, petcoke, alternative fuels) and their impact on kiln operation.

3.      preheater profiles and material flow: Understanding the stages of a preheater (calciner, cyclone stages, preheater stages) and material flow.

4.      Clinker cooling and coolers.

5.      By pass system

6.      Environmental considerations.

7.      Air, mass and heat balance