Cement Manufacturing
Cement Plant Operations
Equipment and Process Functions in the Cementing Industry: Part (2)
Part two: the pyroprocessing line. Preheater, calciner, kiln, burner and cooler.
- Duration
- 5 days
- Contact hours
- 30
- Level
- Intermediate
- Fee from
- On enquiry
Overview
The second part takes the hottest and most expensive equipment in the plant. It covers preheater cyclone design and the separation efficiency that governs it, calciner types and their combustion behaviour, the rotary kiln as a mechanical machine with tyres, rollers and a drive, burner construction, and clinker coolers with their recuperation duty. Mechanical condition is given real attention here, because a kiln out of alignment is a problem that takes a shutdown to fix.
Who should attend
Kiln operators and production supervisors, mechanical and maintenance engineers, process engineers, and refractory and burner specialists.
What you will be able to do
- Describe the function and design logic of each pyroprocessing component.
- Explain cyclone separation efficiency and pressure drop.
- Assess kiln mechanical condition and alignment.
- Compare cooler types on recuperation and reliability.
- Relate an equipment condition to a process symptom.
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
- Cyclone stages, separation efficiency and pressure drop
- Riser ducts and build up
- Gas and material flow through the tower
Day 2
Calciner
- Calciner types and configurations
- Combustion and residence time
- Degree of calcination and its control
Day 3
Rotary kiln
- Shell, tyres, rollers and thrust
- Drive and girth gear
- Alignment, ovality and shell condition
Day 4
Burner
- Burner construction and nozzle arrangement
- Primary air and momentum
- Multi fuel capability
Day 5
Cooler
- Grate and planetary coolers
- Recuperation efficiency
- Snowman, red river and other cooler faults
What you leave with
- A pyroprocessing equipment register with functions and limits.
- A kiln mechanical inspection checklist.
- A cooler performance assessment.
Dates and fees
| Dates | Location | Format | Fee |
|---|---|---|---|
| 23 to 27 November 2026 | Accra, Ghana | Classroom | US$1,500 |
| 30 November 2026 to 4 December 2026 | Dubai, United Arab Emirates | Classroom | US$1,500 |
| 7 to 11 December 2026 | Cape Town, South Africa | Classroom | R15,000 |
| 14 to 18 December 2026 | Kampala, Uganda | 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.