Cement Factory Quality Control Course
A six-week modular course exploring the quality control of cement manufacture, including
the different quality control challenges faced by different cement factories around
the world, plus the philosophies, testing, tools and equipment used to address those
quality control challenges.
Course Content
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Module 1 explores the quality control challenge presented by cement manufacture.
Cement is a hydraulic binder used in conjunction with other materials whose performance
can only inferred and predicted during its manufacture. As a consequence there is
an overriding requirement to minimise variability in material composition and processing
throughout the manufacturing process. Quality assurance systems must be developed
to control the composition of all inputs to the manufacturing process and all processing
conditions. Cement products may be developed for multiple applications but the requirement
to minimise variation remains paramount.
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Module 2 – Statistical process control (SPC) relies on the centering of quality targets
on the requirements of the customer or application, followed by the reduction of
the variation about those targets to ensure that non-compliant material is never
produced. It is therefore the methodology to be used in the quality control of cement
manufacture and the main topic of module 2 of the course. This use of statistical
process control needs to extend far beyond the laboratory and composition testing
of the materials. It needs to be extended to control the manufacturing conditions
within the process. Progressive reduction of variation using SPC techniques leads
to the continuous improvement which is demanded of all quality management systems.
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In module 3 we explore the detail of the quality control throughout the cement manufacturing
process. Raw material chemistry control and raw mix design, kiln feed particle size
and reactivity control, clinker real mineralogy control via microscopy or XRD. Cement
surface area and particle size distribution, gypsum dehydration and calcium sulphate
mineralogy, extender quality and storage or transportation considerations. Finally
the physical testing of cement to ensure that the manufacturing quality control
addresses the needs of the cement in its concrete and mortar applications.
Course Material
Throughout the course the lectures are supplemented with exercises allowing participants to relate
course material to their cement factories, or
the cement factories of their clients in the case of equipment or service suppliers
to the cement industry. Certification is achieved by completing a satisfactory
level of exercises, and by end of module exams.
The course is complete with downloadable handouts of the lectures, exercises,
and reading material for the training record.
Next Course Starts:
18 August 2008
Or select a course start date:
Cost
The cost of the Cement Factory Quality Control online training course is:
UK£500
Eur€700
US$1000
Reductions for group bookings at the following rate:
3 Students - 10% discount
4-5 Students - 15% discount
6 + Students - 20% discount
All discounts are applied automatically during checkout.
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Certification
Students who successfully complete the course are awarded a certificate and a copy
of the Cement Plant Operations Handbook.
Sample Lecture
View a sample lecture