Vocational training course for shift foremen and middle management of the cement industry in Russian 27 August 2015
Advanced training for shift foremen Concept: Training course was developed based on the training and education programme which has been provided for over 50 years by the VDZ The concept was adapted to the requirements and specifics of CIS Countries Objective: To extend the professional knowledge about production of cement
Target group of the training course Target group: Middle management of cement plants Junior engineers Shift foremen and control room operators Qualified personnel Newcomers to the cement industry
Details of the training course Duration: consists of 2 blocks 4 weeks each Venue: training centre around Dusseldorf Language of the course: Russian Presenters: preferably Russianspeaking experts with many years of experience in teaching and working in cement production
Concept of the training course Specially adapted program of the training course based on the requirements of the client. For example: wet-process cement production cement grinding systems with an open circuit mill Recap of the basic knowledge at the very beginning of the course Special seminar on the topic Learning how to learn" to improve the efficiency of the learning process
Concept of the training course Training course covers all stages of cement production process from the raw material extraction to the shipment of the final product Practical modules: Simulation and modelling of the technological processes by means of the simulator tool - Simulex Maintenance and inspection of the plant equipment Tour to one of the German cement plants Visiting the laboratories of the Research Institute of VDZ to see the analyses provided there
Scope of the training course Around 10 to 20 trainees in a group Interactive learning Combining theory with practice Intensive experience exchange Repeating the material of the previous day Cross checking knowledge through a final test in each subject Handing out the training material Supporting the knowledge through the online courses during the break between the 1 st and 2 nd blocks After successful participation handing a VDZ certificate
Main topics of the 1 st block Recap of the basic knowledge: Mathematics Physics Chemistry Learning how to learn raw material extraction quarry crusher raw material handling conveyor bag filter raw material preparation preheater Material technology Raw material extraction Raw material handling Grinding technology of cement and coal pre-blending hall raw mill
Main topics of the 2 nd block Clinker production and burning technology clinker production Clinker silo cement grinding Preventive and condition based maintenance shipping Instrumentation and automation kiln clinker cooler cement mill Operational case studies Refractory materials and installations clinker silo with Simulex On-site practical exercises
Classroom training Interactive training with different presenters, specialised in different topics Different techniques to involve participants in the learning process, e.g. evaluation, discussing, exercises Possibility to ask questions in small groups in order to ensure that all participants get sufficient and substantial answers Relation to the practice and real-life examples from the cement industry Test questions and exercises to monitor learning progress
- SIMULEX with Simulex Simulating clinker burning and cement grinding processes The model of the simulator could be adapted to the layout of client s plant Simulator available in Russian Common exercises on the simulator: Heat-up of the rotating kiln Start-up grinding systems (raw, cement and coal mills) Optimisation of the production process Identifying and correcting system errors and malfunctions
Cement plant visit and installation of refractory material
Example of the schedule of 1 st block Week Monday Tuesday Wednesday Thursday Friday Morning Arrival Learning how to learn Technical chemistry Mathematics for engineers Mathematics for engineers 1 Afternoon Learning how to learn Introduction to the VDZ e-learning platform Learning how to learn Technical chemistry Technical chemistry Morning Technical chemistry Materials technology Materials technology Materials technology Materials technology 2 Afternoon Mathematics for engineers Mathematics for engineers Physics Physics Physics 3 Morning Physics Physics Afternoon Raw material extraction and handling Raw material extraction and handling Raw material extraction and handling Raw material preparation and grinding technology Raw material preparation and grinding technology Raw material extraction and handling Raw material extraction and handling Raw material preparation and grinding technology 4 Morning Materials technology Materials technology Materials technology Afternoon Raw material preparation and grinding technology Raw material preparation and grinding technology Raw material preparation and grinding technology Visit to Researche Institute of VDZ Raw material preparation and grinding technology Departure
Example of the schedule of 2 nd block Week Monday Tuesday Wednesday Thursday Friday 1 Morning Afternoon Clinker production and burning technology Preventive maintenance Clinker production and burning technology Condition based monitoring Condition based monitoring Clinker production and burning technology Clinker production and burning technology Instrumentation and automation Instrumentation and automation Clinker production and burning technology Morning Efficiency of electrical energy usage Environment and emission monitoring Environment and emission monitoring Environment and emission monitoring Operational case studies 2 Afternoon Clinker production and burning technology Clinker production and burning technology Operational case studies Operational case studies Operational case studies 3 Morning Afternoon 4 Morning Afternoon Refractory materials and installations Plant maintenance and equipment reliability Refractory materials and installations Plant maintenance and equipment reliability Visit to a cement plant Refractory materials and installations Plant maintenance and equipment reliability Departure
Successful training courses General facts Held twice in 2014: January April and September December altogether 27 trainees from cement plants located in the Ukraine, Russia, Georgia and Kazakhstan Qualification of the participants: shift foremen, maintenance and process personnel with various experience in dry and wet process of cement manufacturing Realisation of the concept presented Organisation of social activities and short trips on weekends for the teambuilding purposes
First successful training course Stages Grinding technology course (SIMULEX ) Sample preparation On site training
Successful training courses Feedback The course about the clinker burning process was excellent! I found both the theoretical and practical parts of the course about refractory installation very interesting and useful. The SIMULEX training was grate! During the lectures I got some new ideas regarding my every day work in the plant. The organisation of the training course was on the highest level. Thank you very much! The training course was carried out at the very high level since everything was arranged perfectly! We had the luck to meet our colleagues from other plants and, besides training, to exchange our experience in solving production problems with them. Create a third block. We would like to come again!
Thanks for your attention!