Cement Manufacturing
Cement Plant Operations
Cement Manufacturing Typical Incidents Part (2)
Part two: process incidents. Kiln upsets, blockages, cooler failures and the chains of events behind them.
- Duration
- 5 days
- Contact hours
- 30
- Level
- Intermediate
- Fee from
- On enquiry
Overview
This part works through process incidents that have actually happened in cement plants, reconstructed as sequences rather than presented as conclusions. Preheater blockages, kiln flushes, cooler snowmen, refractory failures and silo problems are each followed from the first deviation through the decisions taken to the outcome. The analytical method is the point: participants learn to read an incident backwards to the decision that made it likely, which is more useful than knowing what happened at somebody else's plant.
Who should attend
Process and production engineers, shift supervisors and control room operators, technical services staff, and anybody conducting incident investigations.
What you will be able to do
- Reconstruct an incident as a sequence rather than a single cause.
- Recognise the early deviations that precede common upsets.
- Identify the decisions that made an outcome likely.
- Apply a structured investigation method to a process incident.
- Convert a finding into a control somebody will actually use.
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, live online, in house.
Programme outline
Day 1
Preheater incidents
- Blockages and their build up
- Cyclone and riser failures
- Clearing operations and their own hazards
Day 2
Kiln incidents
- Flushing and unstable burning zone
- Ring formation and collapse
- Refractory failure and shell damage
Day 3
Cooler and downstream
- Snowman and grate problems
- Clinker handling failures
- Silo and conveying incidents
Day 4
Investigation method
- Timeline reconstruction
- Causal analysis without blame
- Data needed, and when it is already lost
Day 5
Acting on it
- Corrective actions that get implemented
- Sharing learning across shifts
- Checking a control is still working a year later
What you leave with
- A reconstructed incident analysis.
- An early warning indicator list for common upsets.
- A corrective action set written to be implementable.
Dates and fees
| Dates | Location | Format | Fee |
|---|---|---|---|
| 23 to 27 November 2026 | Maseru, Lesotho | Classroom | R15,000 |
| 30 November 2026 to 4 December 2026 | Durban, South Africa | Classroom | R15,000 |
| 7 to 11 December 2026 | Dubai, United Arab Emirates | Classroom | US$1,500 |
| 14 to 18 December 2026 | Cairo, Egypt | 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.