Cement Manufacturing
Cement Plant Operations
Advanced Process Technology of Cement Manufacturing
Optimising an existing line: where the energy goes, where the capacity is lost, and what to change.
- Duration
- 5 days
- Contact hours
- 30
- Level
- Advanced
- Fee from
- US$1,500
Overview
This week assumes the process is understood and goes after performance. It is built on measurement: a proper heat and mass balance, gas and solids flows established rather than assumed, and separator and mill efficiency calculated from samples. From that base it works through the levers, in the order they usually pay: false air, cooler efficiency, calciner combustion, separator tuning and alternative fuel substitution. Every recommendation is expected to be supported by a number.
Who should attend
Process engineers and plant managers, production superintendents, energy managers, and technical staff responsible for plant performance.
What you will be able to do
- Build a heat and mass balance for a real line.
- Locate energy losses and rank them by recoverable value.
- Assess cooler, preheater and separator efficiency from measurement.
- Identify the bottleneck rather than the loudest complaint.
- Build an improvement case with figures behind it.
How it is taught
Short input, then work, across 5 days of roughly 6 teaching hours each. Exercises run on situations delegates bring rather than on a case study written for a different organisation. Cohorts are capped so that everybody is asked something.
Available as classroom, in house.
Programme outline
Day 1
Measurement first
- Gas and solids flow measurement
- Sampling for balance work
- Instrument reliability, and how much to trust a reading
Day 2
Heat and mass balance
- Setting the boundary
- Building the balance and closing it
- Reading the losses
Day 3
Pyroprocessing efficiency
- False air and its cost
- Preheater and calciner performance
- Cooler efficiency and recuperation
Day 4
Grinding efficiency
- Mill performance assessment
- Separator efficiency and Tromp curves
- Circulating load and its effect
Day 5
Making the change
- Bottleneck analysis
- Alternative fuels and their process effects
- Building and defending the investment case
What you leave with
- A heat and mass balance for your own line.
- A ranked loss register.
- An optimisation plan with expected savings quantified.
Dates and fees
| Dates | Location | Format | Fee |
|---|---|---|---|
| 23 to 27 November 2026 | Dar es Salaam, Tanzania | Classroom | US$1,500 |
| 30 November 2026 to 4 December 2026 | Kampala, Uganda | Classroom | US$1,500 |
| 7 to 11 December 2026 | Nairobi, Kenya | Classroom | US$1,500 |
| 14 to 18 December 2026 | Dubai, United Arab Emirates | Classroom | US$1,500 |
Fees are per delegate and cover tuition, all programme materials and the certificate. Travel, accommodation and visas are arranged by the delegate. Registration closes two weeks before a programme starts.
Certificate
A GATI certificate recording what was attended, issued after the programme has run and attendance has been taken. Attending at least 80 per cent of the days earns a certificate of completion; attending less earns a certificate of attendance stating exactly what was attended. Every certificate carries a code that anybody can check against GATI's own record.
It records participation. and GATI does not claim one it does not hold.