Process Training

Open to All. Requires Conference Registration. $50 per module or $200 for 4+

Monday, May 5, 2025
8:30 AM - 10:15 AM
Process Training Module 1 - Refractory Failure Analysis
 

[Open to All. There is a cost and requires Registration]

Presented by Andy Porterfield, Refractory Representative, Inferno

This module will provide an overview of the importance of accurate analysis, the challenges of conducting failure analysis and some factors that contribute to non-specific failures. In addition, specific types of kiln brick failures and the conditions that lead to these failures will also be examined with ways to prevent them. Andy Porterfield of Krosaki Brick will lead the session. He has served in all aspects of the refactory industry for nearly 40 years including research, product development, failure analysis, testing, quality control, and technical sales, with the majority of this time spent in the field as a manager for various refractory installation contractors. 

10:30 AM - 11:45 AM
Process Training Module 2: Refractory Training
 

[Open to All. There is a cost and requires Registration]

Presented by John Stephansky, Sales Manager, Reno Refractories, Inc

This presentation delves into the progression of anchoring systems used in contemporary cement and lime plants. It includes an overview of historical failure issues and their resolutions, focusing on the technical benefits of different alloy choices, anchor types, spacing, thermal profiles, proper welding techniques, and the critical importance of analyzing anchoring selections.

1:00 PM - 4:45 PM
Process Training Module 3 - Training on Basics of Fan Performance
 

[Open to All. There is a cost and requires Registration]

Presented by Vern Martin P. Eng, Sr. Mechanical Engineer, Flowcare

A half-day workshop focusing on fan system optimization, reliable operation and achieving ideal capacity requirements. Attendees will be provided with practical information that extends from project concept to long term operation of fan systems.  Vern Martin P.Eng. is a senior mechanical engineer and partner in FLOWCARE Engineering Inc.; a company specializing in fan technical consulting services. He has primarily been involved in energy optimization studies and the troubleshooting of fans with performance, noise, vibration, control or failure problems.

Tuesday, May 6, 2025
1:00 PM - 2:45 PM
Process Training Module 4 - Kiln Mechanical Maintenance
 

[Open to All. There is a cost and requires Registration]

Presented by Brian Greenlees, Director of Operations and Kyle Kogelmann, Field Service Manager, A-C Equipment Services

Have you noticed any bent or broken filler bar components on your kiln? Are you experiencing frequent refractory failures near riding rings (kiln tires)? Are your filler bars (pads) or tire retainers wearing too quickly? Are you constantly repairing welds or shutting down unexpectedly due to filler bar issues? If so, a review of your existing filler bar/tire retainer system and tire creep could be warranted to help reduce repair costs and down time. Designing for the proper amount of creep and other important kiln maintenance topics will be discussed. 

3:00 PM - 4:45 PM
Process Training Module 5 - Kiln Hot Spot Troubleshooting
 

[Open to All. There is a cost and requires Registration]

Presented by Jeff Bump, Owner of C3S

A dynamic discussion of the various causes of kiln hot spots and how to avoid, recognize them when they occur, and mitigate them in order to sustain kiln operation (if possible) and prevent damage to equipment.  Topics include: tools and techniques for monitoring and/or alleviating hot spots; operating conditions that impact refractory life; coating formation and stability; fuel selection, composition, and dosing; burner management; and more.  Jeff Bump, Owner of C3S, will lead this dynamic module.

Wednesday, May 7, 2025
1:00 PM - 2:45 PM
Process Training Module 6 – Interpreting Material Flow Test Reports and Real World Applications
 

[Open to All. There is a cost and requires Registration]

Presented by Scott Miller, Solids Handling Technology, Inc

An introduction to material flow reports and how to use them. This session will provide an overview of the typical tests used to characterize the properties of bulk solids for handling materials in storage silos, bins, and hoppers. Attendees will gain an understanding of the interpretation of the typical test reports provided from these types of tests and how to use them. Scott Miller, consultant at Solids Handling Technologies, Inc., will present this training session.

3:00 PM - 4:45 PM
Process Training Module 7 - Finish Mill Problem Solving
 

[Open to All. There is a cost and requires Registration]

Presented by Jeff Bump, Owner of C3S

An interactive lecture covering the most common (and some not so common) factors influencing the production rate of a ball mill, and the various ways cement plant engineers and operators can try to optimize their performance.  Topics include: material characteristics; equipment condition; ball charge design; and more.  Jeff Bump, Owner of C3S, will guide this module which should appeal to any engineer charged with adapting their mill to the new realities of IL and blended cements introduced into the marketplace.