Vocational training course for

shift foremen and middle

management of the cement

industry in Russian

27 August 2015

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

Advanced training for shift foremen

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

Duration: consists of 2 blocks 4

weeks each

Venue: training centre around

Dusseldorf

Language of the course: Russian

Presenters: preferably Russian-

speaking experts with many years of

experience in teaching and working in

cement production

Details 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

Concept 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 1st and 2nd blocks

After successful participation handing a VDZ certificate

Scope of the training course

Main topics of the 1st block

raw material extraction

raw material handling raw material preparation

quarry

conveyor

bag filter

pre-blending hall

crusher

preheater

raw mill

Recap of the basic knowledge:

– Mathematics

– Physics

– Chemistry

„Learning how to learn“

Material technology

Raw material extraction

Raw material handling

Grinding technology of cement and

coal

Clinker production and burning

technology

Preventive and condition based

maintenance

Instrumentation and automation

Operational case studies

Refractory materials and installations

Simulator training with Simulex®

On-site practical exercises

Main topics of the 2nd block

Clinker silo

kiln clinker cooler

shipping

clinker production

cement grinding

clinker silo

cement mill

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

Simulator training - SIMULEX®

Simulator training 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 1st block

Week Monday Tuesday Wednesday Thursday Friday

1

Morning

Arrival

Learning how to learn Technical chemistry Mathematics for

engineers

Mathematics for

engineers

Afternoon Learning how to learn Introduction to the VDZ

e-learning platform Learning how to learn Technical chemistry Technical chemistry

2

Morning Technical chemistry Materials technology Materials technology Materials technology Materials technology

Afternoon Mathematics for

engineers

Mathematics for

engineers Physics Physics Physics

3

Morning Physics Physics Raw material extraction

and handling

Raw material

preparation and

grinding technology

Raw material

extraction and

handling

Afternoon Raw material

extraction and handling

Raw material extraction

and handling

Raw material

preparation and

grinding technology

Raw material extraction

and handling

Raw material

preparation and

grinding technology

4

Morning Materials technology Materials technology Materials technology

Visit to Researche

Institute of VDZ

Raw material

preparation and

grinding technology

Afternoon

Raw material

preparation and

grinding technology

Raw material

preparation and

grinding technology

Raw material

preparation and

grinding technology

Departure

Example of the schedule of 2nd block

Week Monday Tuesday Wednesday Thursday Friday

1

Morning Clinker production and

burning technology

Clinker production and

burning technology

Condition based

monitoring

Clinker production and

burning technology

Instrumentation and

automation

Afternoon Preventive maintenance Condition based

monitoring

Clinker production and

burning technology

Instrumentation and

automation

Clinker production

and burning

technology

2

Morning Efficiency of electrical

energy usage

Environment and

emission monitoring

Environment and

emission monitoring

Environment and

emission monitoring

Operational case

studies

Afternoon Clinker production and

burning technology

Clinker production and

burning technology

Operational case

studies

Operational case

studies

Operational case

studies

3

Morning Simulator training

(Simulex®)

Simulator training

(Simulex®)

Simulator training

(Simulex®)

Simulator training

(Simulex®)

Simulator training

(Simulex®)

Afternoon Simulator training

(Simulex®)

Simulator training

(Simulex®)

Simulator training

(Simulex®)

Simulator training

(Simulex®)

Simulator training

(Simulex®)

4

Morning Refractory materials and

installations

Refractory materials

and installations

Visit to a cement plant

Refractory materials

and installations

Departure

Afternoon Plant maintenance and

equipment reliability

Plant maintenance

and equipment

reliability

Plant maintenance and

equipment reliability

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 Simulator training (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!