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
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!“