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Technical, Mechanical, & Engineering Yogyakarta

Pyro Process – Operations and Process

OBJECTIVES

The purpose of the course is to give operators, production supervisors, and process engineers the skills and knowledge to Optimize the Pyro Processing System.

OUTLINE

1. Kiln Operation

2. Process and Kiln System Design Considerations

• Kiln Zones
• Raw Material Characteristics
• Chemical Reactions in the Kiln
• Liquid Phase and Importance of Iron and Aluminum content

3. Calciner Operation

• Fuel Types and their Characteristics
• Alternative Fuels use in the Calciner and Impact in System Operation

4. Combustion Theory

• Heat Transfer
• Flame Formation
• Main Burner, changes that affect flame formation and lead to better burning conditions

5. Clinker Coolers

• Clinker Cooler types
• Cooler Operating Philosophy and Optimization of Clinker Coolers

6. Heat Balances

• Heat and Material flows
• Measurements in the Pyro Process System (Temperature, Pressure, O2 Profile)
• Measurements in the Cooler, Airflows, Temperatures and Pressures
• Heat Balance Calculations

7. Optimization of Heat Consumption

• Kiln Feed Burnability
• Distribution of Air and Losses in the Cooler
• Clinker Formation
• Behavior of Volatile Matter
• Volatile Matter Work Session

8. Emissions of NOx, SOx, Particulates, Mercury, etc from Cement Kilns

• New Emission Standards
• Bag House, Operation and Maintenance
• Refractory Considerations
• Practical Sessions with the Use of Pyroprocess Simulation/ECS Cemulator Software
• Starting and Stopping the Kiln using the ECS Cemulator Software
• Interaction of Control Loops between the Kiln and Cooler areas
• Various Disturbances
• System Cooling Down
• Loss of Fuel in the Calciner or Kiln Burner
• High Bed Depth in the Cooler
• Kiln Push
• Change in Pressure Profiles in the Preheater
• Main Bag House issues
• Kiln Ring formation/Kiln Ring fall
• Cyclone Plug
• High CO

9. Kiln System Shut Down

• Considerations during a Short Shut Down
• Considerations during a Maintenance Shut Down
• Evaluation running the Kiln System to Full Production

TRAINING METHOD

Presentation

Discussion

Case Study

Evaluation

FACILITY

Training Kit

Handout

Certificate

Lunch + 2 X Coffee Break

Souvenir

TRAINING FEE for Pyro Process – Operations and Process

Rp7.000.000,-/Peserta /Non Recidential

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