Training Topics for Operators

Contents

I. Raw material preparation1. Introduction for cement raw materials

1.1.1.2.

2. Crusher

Chemical composition of raw materialsNature and physical properties

2.1. Process description of crusher unit (process flow)2.1.1.2.1.2.2.1.3.

Limestone crusherCoal crusherGypsum crusher2.2.Mechanical components and instruments of the crusher function and working principle

2.3.2.4.2.5.2.6.2.7.

3. Stacker

working principle of the crushers and typesstartup and stoppage sequenceInterlocking (startup interlock ,operational interlock , safety interlocks) Inspection points before start up and stoppageOperational parameters and their control system

3.1. Stacker operation principle3.2. Mechanical components of stacker their function and working principle3.3. Stacking methods3.4. Working principle of jib arm lifting and lowering piston and hydraulic circuit3.5. Operating procedure of stacker (shunting and pile changing)3.6. Control system of the stacker operation

3.6.1. Control modes(local and central)and Signal relation between crusher and stacker

4. Reclaimer4.1. Types of reclaimers and working principle4.2. Control system of the reclaimers

4.2.1. Control modes (local and central)4.3. Mechanical components and instruments of reclaimer their function and working principle

5. Proportioning unit5.1. Mechanical components and instrument function5.2. Filling procedure of proportioning bins5.3. Raw mix design

II. grinding unit and controlled flow silo1. Grinding system and circuit of VRM(RAWMILL AND COAL MILL)

1.1.1.2.1.3.1.4.1.5.1.6.

Process description of raw mill and coal millMill typesOperating principle of vertical roller mill Separator types and working principle Mechanical equipment and instrument functionControlled parameters

2. Operation of vertical roller mills

2.1. Checking before start up procedure

2.1.12.1.22.1.32.1.42.1.52.1.6

operation of the mill and parameters to be controlledshut down procedure during normal and emergency

situation Interlocking(start up, operation, safety interlocks) Optimization of vertical roller millSafety precautionsOperational problems and their remedies

3. Controlled flow silo

3.1. Working principle of homogenization silo

3.2. Mechanical equipments and instruments functions

3.3. Operation of homogenization silo

o o o o o o oo

Checking before start upStart-upOperationShutdown during normal situationShut down during emergency situationInterlockingSafety precautionsOptimization of the system

3.4. Types and operating principles of controlled flow silo

III. Cement preparation unitA. Grinding unit1. Grinding system and circuit

1.1.1.2.1.3.1.4.

Process description of cement millOperating principle of ball millsMechanical equipments and instruments functionSeparator working principle2. Operation of cement mill

2.1. Checking before start up procedure

2.2.2.3.

operation of the mill and parameters to be controlledshut down procedure during normal and emergency situation2.4. Interlocking (start up, operation, safety interlocks)

2.5. Safety precautions2.6. Operational problems and their remedies

3. Cement silo’s3.1.3.2.3.3.

3.3.1.3.3.2.3.3.3.3.3.4.3.3.5.3.3.6.3.3.7.

Working principle of silo extractionMechanical equipments and instrument function Operating procedure of cement extraction Checking before start upStart-upOperationShutdown during normal situationShut down during emergency situationInterlockingSafety precautions

4. Cement chemistryB. PACKING UNIT

1. Type of packers2. Working principles of packers3. Process flow4. Operation of packers

4.1. Checking before start-up

4.2. Start-up

4.3. Operation of the unit and parameters to be controlled

4.4. Shutdown during normal and emergency situation

4.5. Interlocking

4.6. Safety precautions

4.7. Possible operation problems and their remedies

4.8. Setting values of parameters and actions to be taken during deviation fromsetting values.

5. Loading Bays operating procedure

6. Mechanical equipments and instruments function

Operators training schedule

THE TRAINING PERIOD

S.N Training topics Training duration Trainer Trainees RemarkDAYS

A RAWMATERIAL PREPARATION HAILEMARIAM/ EXAM AT THE END OF

1 Introduction to cement raw materials 2

2 Crusher 2 ALL OPERATORS3 Stacker 24 Recalimer 15 Proportioning unit 3

TOTAL 10B GRINDING AND CONTROLLED FLOW SILO SAMUEL1 Grinding system of vertical roller mills 5 ALL OPERATORS2 Operations of vertical roller mill 43 Controlled flow silo 2

TOTAL 11C PYROPROCESSING HAILEMARIA

M GEZAHEGN1 Process description of pyro process 1

2 Operation of kiln 5 ALL OPERATORS3 Kiln 14 Fuel 25 Combustion theory 2

TOTAL 11D CEMENT MILL AND PACKING WONDAMAGEGN1 Grinding system of ball mill 42 Operation of cement mill 2 ALL OPERATORS3 Cement silo 14 Cement chemistry 15 Packing unit 1

TOTAL 9

IV. PYROPROCESSING

1. Process description of pyroprocess1.1.1.2.1.3.

Process flowMechanical equipment and instruments function

2. Operation of kiln2.1. Burning system

2.1.1.Control parameters in the pyroprocessing2.1.2.Reactions in pyroprocessing

2.2. fuel preparation2.2.1.Control parameters

2.3.2.4.2.5.2.6.2.7. Kiln3.1.3.2.3.3.

Preparation before start upStart up procedureStop procedure in normal and emergency situationProcess interlocks (start up, operational, safety interlocks) Safety precautions

3.HistoryTypes of kiln processStandard kiln systems

4.5.6.

Fuel types and characteristicscombustion theory clinker chemisry