Online Training

Cement Kiln Process Chemistry Course

Understand the chemical processes that govern kiln efficiency, clinker quality, volatile cycles and environmental emissions.

USD$ 1000.00 Group discounts automatically
applied at checkout

Duration6 Weeks

LocationOnline

Next Start Dates

12 Oct 2026

Schedule 2026 Browse

Highlights:

Flexible to your schedule
Downloadable materials
Practical exercises
Module exams
Certificate

What You'll Learn

Explain burnability, calcination, sintering and clinker mineral formation
Interpret phase equilibria, lime saturation and Bogue composition
Diagnose alkali, chloride and sulphate cycles and redox effects
Relate kiln chemistry to CO2, NOx, SO2 and trace-metal emissions

Course Breakdown

Module 1: Kiln efficiency and productivity 10 lessons

Explains how raw materials combine into clinker minerals, covering thermodynamics, burnability, calcination, sintering, mineralisation, combustion and internal and external volatile cycles.

Introduction
Module 1.1 - Quiz
Module 1.2 - Burnability
Module 1.2 - Burnability Exercises
Module 1.3 - Variability
Module 1.3 - Variability Exercise
Module 1.4 - Calcination
Module 1.4 - Quiz
Module 1.5 - Sintering
Module 1.5 - Sintering Exercises
Module 1.6 - Mineralisation
Module 1.6 - Quiz
Module 1.7 - Alkali Cycles
Module 1.7 - Alkali Cycle Exercise
Module 1.8 - Chloride Bypasses
Module 1.9 - Sulphates
Module 1.9 - Sulphates Exercise
Module 1.10 - Combustion
Module 1.10 - Combustion Exercises
End of Module 1 Exam

Module 2: Clinker product quality 10 lessons

Examines phase equilibria, the CaO-SiO2-Al2O3-Fe2O3 system, lime saturation, Bogue mineralogy, polymorphs, redox conditions and mineralised clinker.

Introduction
Module 2.1 - Quiz
Module 2.2 - CSAF System
Module 2.2 - Exercise
Module 2.3 - Lime Saturation
Module 2.4 - Bogue Composition
Module 2.4 - Exercise
Module 2.5 - Deviation from Bogue Compound Composition
Module 2.5 - Exercise
Module 2.6 - K2O and P2O5
Module 2.6 - Exercise
Module 2.7 - SS Polymorphs
Module 2.8 - Redox
Module 2.8 - Exercise
Module 2.9 - Soluble Alkalis
Module 2.10 - Mineralised Clinker
End of Module 2 Exam

Module 3: Safety and environmental emissions 10 lessons

Connects kiln chemistry with carbon reduction, CO and THC formation, dioxins, NOx and SO2 abatement, plume behaviour and the control of mercury and thallium.

Module 3 - Introduction
Module 3.1 - Quiz
Module 3.2 - CO2 Reduction
Module 3.2 - Exercise
Module 3.3 - CO Sources
Module 3.3 - Exercise
Module 3.4 - Dioxins
Module 3.5 - NOx Formation
Module 3.6 - NOx Abatement
Module 3.7 - SO2 Abatement
Module 3.8 - Plumes
Module 3.9 - Hg and Tl
Module 3.10 - Course Conclusion
End of Module 3 Exam

Course Overview

This six-week online course provides a structured understanding of the chemistry governing cement kiln performance. It begins with raw-material combination and clinker formation, then examines the mineralogical factors controlling clinker quality before connecting process chemistry with safety and environmental performance.

Across 30 technical lessons, participants study burnability, variability, calcination, sintering, volatile cycles, phase equilibria, Bogue composition, polymorphs, redox conditions and emissions-control chemistry. Exercises, quizzes and three module examinations reinforce the material, supported by downloadable lecture handouts and reading resources. Allow approximately five hours of study per week.

Reasons to Attend

Stabilise Kiln Operation Understand the chemistry behind burnability and process variation
Improve Clinker Quality Connect phase composition with product performance
Control Volatile Cycles Diagnose alkali, chloride and sulphate behaviour
Manage Emissions Apply chemistry to practical abatement decisions

Who Should Attend

Kiln and Process Engineers Strengthen diagnosis of kiln-performance problems
Quality and Laboratory Teams Interpret clinker mineralogy and composition
Environmental Managers Understand the origins and control of kiln emissions
Equipment Suppliers and Consultants Support chemistry-led plant improvement projects

Instructor

Dr Michael Clark

Senior Cement Process Engineer
40+ Years of Experience

Dr Michael Clark combines extensive cement-process experience with specialist knowledge of kiln chemistry, helping professionals connect mineralogy and reaction mechanisms with day-to-day plant performance.

Industry Feedback

The burnability section helped us explain why small raw-mix changes were having such a large effect on kiln response.

A clear treatment of alkali and sulphate cycles. It gave me a better framework for investigating build-up problems.

The clinker-quality module made phase equilibria and Bogue calculations much easier to apply in our laboratory work.

I particularly valued the direct link between process conditions, emissions formation and the available abatement options.

FAQ

How is the course structured?

The six-week course is divided into three two-week modules covering kiln efficiency, clinker quality, and safety and environmental emissions.

How much chemistry knowledge do I need?

A cement-industry or technical background is helpful, but the programme develops the underlying chemical principles progressively and connects them to practical kiln operation.

Are calculations and exercises included?

Yes. Applied exercises and quizzes reinforce the chemistry and help participants relate the concepts to their own plant data and operating conditions.

Do I receive a certificate?

Yes. Certification is awarded after satisfactory completion of the required exercises, quizzes and end-of-module examinations.

Are course materials downloadable?

Yes. Lecture handouts and supporting reading material are available to download for continued reference.

What support is available?

Participants can contact the course instructor by email when technical questions arise during the programme.