Process Measurements and Calculation Bible for Kiln Experts
Position yourself as a Kiln Process Expert by Learning Core-Concepts for kiln Operation Optimization
Training Mode
Online Training +3 one to one on-demand coaching sessions
Access Validity
1-year from enrolment
Best Suited For
Consultants, Process Engineers, CCR-Operation Team, Process Managers
What will you get from this training
This course imparts and enhances your process expertise in the pyro section in particular and in general, it will make you an expert in using process measurements with portable instruments for process audits and analysis. Carry on combustion performance analysis and establish all pyro Key Performance Indicators as Process KPIs, Quality KPIs, Productivity KPIs, and Reliability KPIs to mention a few.
You will learn the skill of using correctly portable process measurement instruments. You will be able to take correctly gas/air flow measurements using Anemometer, and Pitot tube. You will be able to use correctly a thermocouple/RTD probe to take temperature measurements in ducts and chutes. The use of a radiation pyrometer will be discussed thoroughly. You will learn the proper procedure to take gas samples with a portable gas analyzer.
You will learn everything about the fundamentals of the combustion process. Here you will get an opportunity to understand the mole concept of the chemistry of combustion reactions in your personal space. You will learn about the desired characteristics of good fuel for your purpose. You will learn about the properties of coal, oil, and natural gas which will help you to choose the best fuel for your use in a kiln, calciner, and any other furnace/fired heater. You will understand the formulas for calculating calorific values. You will learn gross calorific value and net calorific value, and their physical significance in the combustion process.
You will learn everything about the combustion reaction of carbon, hydrogen, and sulfur. You will learn How much oxygen is required to burn the fuel and how much CO2, H2O, and SO2 will be produced as flue gases from the combustion of the fuel. By learning this you will be able to calculate how much primary air, secondary air, and tertiary air is required in your kiln system. Not only this, but you will be able to calculate the percentages of different gas components like CO2, H2O, SO2, O2, and N2 at the kiln inlet, calciner outlet, and at any point in the preheater.
This training will enable you to do a professional quality mass and heat balance of pyro-section. Being capable of doing mass and heat balance, you will be capable of identifying the optimization potentials to reduce production costs, reduce CO2 emissions, and enhance productivity, reliability, and sustainability.
For writing Mass Balance, You need to learn about all material streams, their metering, and measuring. In this training, you will learn everything about this. You will learn which material streams are to be taken from calibrated metering systems like kiln feed, and fuel flow. And you will learn how to establish clinker production through direct and indirect methods. You will learn everything about gas/air flow calculations using Anemometer and Pitot tubes.
For writing Heat Balance, You will learn how to identify and calculate all heat streams entering into the system and leaving the system. You will learn all methods and formulas for calculating: Sensible Heat, Calorific Heat, Heat of Evaporation, Heat of clinker formation, Heat associated with de-carbonated CaO, and Heat losses through radiation and convection.
Use-case examples, assessments, and online calculators in each calculation will ensure that the concept is ready to practice and apply in your industrial case. Online Mass and Heat Balance templates will facilitate you to generate a professional quality mass and heat balance for your plant, or for your customer's plant if you are working as a consultant.
We recommend you to skim through the course curriculum below to see in detail which topics are covered in this training course.
Course Highlights
35 Plus video lessons
20 Plus Practical use case examples
20 plus Online calculators for practice
5 Minor assessments to check Progress
1 Major assessment to ensure skill development
Online support on any questions asked within 24 hours
One-on-one student guidance support on demand.
Downloadable Process Log Sheet, Material Sampling Plans, etc
Online Mass & Heat Balance, Combustion Calculations Templates
1-year free access to the data bank, Formula bank, and online templates.
Certificate of completion.
Happy Learners From CIN e-Learning Platform
A senior Chemical Engineer and Managing Director of two companies dealing with AF, aiming to go 100% on alternative fuels in his cement kiln projects took the training and said that "The course has refreshed his skills of doing process audit of pyro process".
Neville Roberts
Chemical Engineer from KSA. "I have taken 2 courses so far and found the lessons very easy to understand, ready to work on in plant and achieved a deep knowledge of pyro process"
ABDULRAHMAN HASSAN ALI ALRAYH
ABDULRAHMAN HASSAN ALI ALRAYH
Chemical Engineer from Egypt. "I have taken 3 courses so far and found the lessons very comprehensive to answer all of my questions about the subject" On his suggestions we have added more use cases to solve day-to-day issues of cement plants.
Mohamed Kasim
COURSE CURRICULUM
- Thermocouple and RTD for temperature measurements.
- Portable Radiation scanner (gun) for temperature measurements.
- Pitot tube for velocity, flow and pressure measurements.
- Anemometer for velocity and flow measurements.
- Pressure probe for static pressure measurements
- Portable gas analyser for flue gas composition analysis.
- Coal properties
- Oil and gas properties
- Definitions, Mole Concept, and Assumptions involved in calculation.
- Combustion-equations of Carbon, Hydrogen, Sulphur
- Calorific Value Calculation
- Minimum Stochiometric Air Calculation
- Minimum Combustion Gas Calculation
- 10 Step Formula to do Mass and Heat Balance of Pyro Section
- Kiln Feed to Clinker Ratio
- Kiln Feed to Clinker Ratio: Solved Use-Cases
- Gas Density Calculation
- Gas Density Calculation: Solved Use-Cases
- Flow measurement [pitot tube and Anemometer]
- Flow measurement [pitot tube and Anemometer]: Solved Use-Cases
- Sensible Heat Calculations
- Sensible Heat Calculations: Solved Use-Cases
- Calorific heat calculations
- Calorific heat calculations: Solved Use-Cases
- Heat of formation calculations
- Heat of formation calculations: Solved Use-Cases
- Heat of evaporation Calculations
- Heat of evaporation Calculations: Solved Use-Cases
- Non-Carbonatic Heat Calculations
- Non-Carbonatic Heat Calculations: Solved Use-Cases
- Radiation and Convection Heat Calculations
- Radiation and Convection Heat Calculations: Solved Use-Cases
- Identification of Material Streams
- Calculations with fuel analysis
- Calculations with fuel analysis: Solved Use-Cases
- Calculations without fuel analysis
- Calculations without fuel analysis: Solved Use-Cases
- Process Measurements for Detailed Mass and Heat Balance
- Process Log-Sheet for Detailed Mass and Heat Balance Project
- Material Sampling Schedule Sheet for Mass and Heat Balance
- Data Recording Required for Preliminary M&H Balance
- Process Log-Sheet for Preliminary Mass and Heat Balance Project
- Material Sampling Schedule Sheet for Preliminary Mass and Heat Balance
- Energy Performance Calculation
- Kiln and Cooler Calculations.
- Cooler Efficiency Calculations
- Kiln Firing Calculation
- False Air Calculation.
- Fan Calculations.
- Quality KPIs of Clinker and Control Levers of Quality
- Burnability KPIs as Control Levers
- Assessment and Audit of Volatile Phenomena in Kiln
- Supplementary Quality Calculations
- Productivity KPI
- Reliability KPI
- Environment KPI
- Final Assessment
Frequently Asked Questions
- The qualification for taking this training course is that you have a basic knowledge of pyro processing.
- You may be a CCR operator preparing in advance for future challenges.
- You may be a Process engineer, with a core responsibility for process analysis and optimization.
- You may be a production supervisor, or production manager, responsible for having a 360-degree awareness, and visualization of the actual process.
- You may be an organization intending to develop your own team capable of working for plant operation optimization.
- Or, you may be someone working as a cement plant operation and optimization consultant.
Upon registration/Enrollment, the entire course will be made available for viewing. Please watch the video lessons, learn the concepts and practice excercises/activities well. During course time you can watch the videos as many times as you like, use the online calculators to practice excrcies and assignments. Training is delevered through recorded and hosted multimedia means like videos, PDF Documents, Online Calculators etc.. In addition you secure Three 1-hours online 1 to 1 session with course with no additional cost. But, In case if you need a additional special one to one coaching on any special topic, this can be arranged on chargeable basis @ USD50/hour coaching sessions.
You will get full support during training time, You can ask any question during study in comment section, you can generate a ticket, you can write direct email to instructor and you can even contact on phone/WhatsApp of course instructor, all required contacts will be emailed to you on course registration.
1-year from the date of enrollment in this training course
- You can enroll into this training at any time you want.
- This course is open at all times, During your training time you will get full support to answer your questions and clearify your doubts.
- Less than 10 % of the course content has been viewed.
- Not attempted the program assessments.
- Haven't downloaded any handouts of the training.
YES, if you have any additional questions regarding this training course please submit a ticket here Customer Support Services
