Topics will range from the theoretical to the practical as further described below.

 

PROCESS 201 TRAINING*

*Note: The Process 201 Training Modules must be registered for separately and require a small fee. The Process 201 Course builds upon the PCA Regional Milling & Pyro Courses (Process 101 Training). It is recommended (though not mandatory) that trainees attend the PCA Regional Courses and/or Process Training Modules at earlier IEEE/PCA Conference(s) before advancing to the Process 201 Level Course.

 

 

Monday

May 02, 2022

 

 

Introduction to Carbon Neutrality –  

This training module will set the stage for the remainder of Monday’s Process Training sessions.  This session will enable participants to gain an understanding of the traditional levers for CO2 emissions reductions, such as:  energy efficiency, lower carbon fuels, lower amounts of clinker in cements, and the use of supplemental cementitious materials.  In addition to cement producers, the implications for equipment suppliers also will be explored.

8:00am

-

9:45am

Carbon Reduction Technologies –  

This training module will review all of the current technologies for carbon reduction, carbon capture, and carbon utilization that have been developed globally to date.   This session will compare and contrast the various technologies and demonstrate the locations that these technologies can be applied in the cement industry.  Again, the implications for vendors and equipment suppliers will be explored in addition to cement producers.

10:15am

-

12:00pm

Lunch  –  Exhibit Hall

12:00pm

-

1:00pm

Carbon Reduction Projects – 

This training module will review already commissioned and/or ongoing Carbon Reduction Projects in the cement industry worldwide.  The basic principles of each project will be discussed as well as the pros and cons of each technology with the objective of allowing the attendees to see for themselves which projects could benefit which plants.  Again, opportunities for cement producers and equipment suppliers will be explored.

1:00pm

-

02:45pm

A Stepwise Approach to CO2 Emissions Reductions

This training module will identify specific steps that individual cement plants can take to reduce their CO2 emissions.  This session will help to empower cement plant personnel to develop their own carbon neutral plans.  This session will create opportunities for vendors, consultancy engineers, and technology providers to assist in the development of plans to lower plant CO2-intensity for individual cement producers.

 

3:15pm

-

5:00pm

 

Tuesday

May 03, 2022 

 

 

The Optimization of Reagents for Controlling NOx Emissions –

The usage of ammonia and urea strongly impact plant operational costs. This training module will present “reality checks” on the amounts of reagent usage by looking at the means & methods to reduce overall usage of costly reagents for optimal effectiveness. 

This training module is developed and presented by Peter Paone of Bridge Gap Engineering.

 

10:00am

-

11:15am

Successful Alarm Management –

What good are process control alarms if they are so frequent that they are continuously silenced by control room operators? This training module will present a strategic approach for the implementation of a quality alarm management system based on the ISA Standard 18.2. 

This training module is developed and presented by John Kline of Kline Consulting.

 

1:00pm

-

2:45pm

State-of-the-Art Reliability & Predictive Maintenance

This training module will present the latest technologies for predictive maintenance including the use of artificial intelligence. 

This training module is developed and presented by Jose Gil of FLSmidth Inc.

 

3:00pm

-

4:45pm

 

Wednesday

May 26, 2021

 

 

Handy Emissions Calculations & Conversions – This training module will enable participants to understand the basic units of measure for environmental emissions measurements. It will educate participants on how to quickly convert between ‘measured values’ in “ppm”, for example, to ‘permit values’ such as “lb/ST clinker” or “mg/m3, dry basis at 7% O2“, for example. 

This training module is developed and presented by Peter Paone of Bridge Gap Engineering.

 

10:00am

-

11:15am

Successful Process Control Strategies –

This training module will present control loop experiences for the successful operation of all major pieces of equipment in a cement plant. Expert opinion and experiences with control loops will be offered. 

This training module is developed and presented by John Kline of Kline Consulting.

 

 

1:00pm

-

2:45pm

Kiln Burner Momentum Calculation and Control –

The objectives of this training module are to learn to calculate burner momentum, to understand the effect of fuel transport air on burner momentum, and to study the recommended momentum values for firing various types of fuels. 

This module is developed and presented by Jean Jung of Fives-Pillard.

 

3:00pm

-

4:45pm

 

Thursday

May 27, 2021

 

 

Preheater Tower Build-Ups, Kiln Balls & Rings, and Cooler Snowman –

This training module will explore various types of build-ups and ring formations that are found in pyroprocessing systems. Cause & effect relationships will be explored as well as recommended mitigation strategies. 

This training module is developed and presented by Peter Paone of Bridge Gap Engineering.

 

10:00am

-

11:15am

Leading Cement Terminal Technology –

Did you know there are more than 500 cement terminals in the U.S. and Canada? This training module will explore the various technologies available and implemented at cement terminals from the smallest rail terminals to the largest barge terminals. 

This training module is developed and presented by John Kline of Kline Consulting.

1:00pm

-

2:45pm

Cement Imports and Import Terminals – 

This training module will explore the various technologies available for import terminals. The current and future status of cement ocean/import terminals will be reviewed. 

This training module is developed and presented by John Kline of Kline Consulting.

3:00pm

-

4:45pm

 

Friday

May 28, 2021

 

 

Production Levers –

This training module will examine the production optimization process and improving operational efficiencies which are often at odds with maximum production. 

This training module is developed and presented by John Kline of Kline Consulting.

10:00am

-

11:15am

 

An Assessment of Your Plant’s Lubrication Practices –

This self-assessment will examine your plant’s practices for its lubrication systems and rank these practices from ‘Poor’ to ‘Mastery’. 

This self-assessment will be moderated by John Kline of Kline Consulting.

 

1:00pm

-

2:45pm

Lubrication Best Practices –

This training module will explore best practices for lubrication systems. Lubrication is the lifeblood of the equipment in the plant. Improving lubrication practices will improve uptime and reduce maintenance costs. 

This training module is developed and presented by John Kline of Kline Consulting.

3:00pm

-

4:45pm