## Frequently Asked Questions

Who can join this workshop on mass and heat balance of pyro process?

Anyone, Yes! anyone who has the knowledge of pyro process and is interested in overall process optimization. Anyone with process knowledge and interest to know the reason of higher power consumption, higher heat consumption can learn to do mass and heat balance.

I recommend learning mass and heat balance to you if you are;

A CCR Operator, and are expecting to deliver the responsibility of production supervisor in near future.

If you are operation supervisor, process engineer, or even production manager responsible to achieve and maintain optimum plant operation, to control cost of production. You must learn the skill of mass and heat balancing. Or, at least you must learn to consider the importance of this subject. So that you can get mass and heat balance of your plant done regularly, and take data driven actions on the basis of that document, to optimize your overall plant operation.

I recommend learning mass and heat balance to you if you are;

A CCR Operator, and are expecting to deliver the responsibility of production supervisor in near future.

If you are operation supervisor, process engineer, or even production manager responsible to achieve and maintain optimum plant operation, to control cost of production. You must learn the skill of mass and heat balancing. Or, at least you must learn to consider the importance of this subject. So that you can get mass and heat balance of your plant done regularly, and take data driven actions on the basis of that document, to optimize your overall plant operation.

What I will learn in this workshop?

In this workshop you will learn to establish, detailed, and preliminary mass and heat balance of pyro section.

In this workshop you will learn the importance of mass and heat balance for plant optimization.

In this workshop you will learn how to calculate various important key performance indicators, like false air in kiln system, specific heat consumption, residence time in calciner- which is very important factor for getting insights about combustion process in calciner, gas velocity in preheater cyclones- providing insights about the spare capacity which can be explored with debottlenecking process.

In this workshop you will learn the importance of mass and heat balance for plant optimization.

In this workshop you will learn how to calculate various important key performance indicators, like false air in kiln system, specific heat consumption, residence time in calciner- which is very important factor for getting insights about combustion process in calciner, gas velocity in preheater cyclones- providing insights about the spare capacity which can be explored with debottlenecking process.

What will be the mode of learning? And what will be the structure of this 7-day workshop for learning mass and heat balance of kiln section?

On day 0, we will meet online on an introduction call. Where I will consider the most important subjects regarding mass and heat balance, like;

1. What is mass and heat balance!. as an activity, and as a tool?

2. What is detailed, and preliminary mass and heat balance?

3. Why should you do, mass and heat balance?

4. When should you do, mass and heat balance?

Day 0 will be analogous to a kickoff meeting to impart inertia to get mass and heat balance done within this one week’s time.

Remember! That it is not an online course where you have months together to study the subject. This is an action based workshop, where I will be working with you for the whole week’s time, and you have to dedicate this one week time as well for developing and doing mass and heat balance.

And at the end of this workshop I want to see you capable to write mass and heat balance of your pyro section. And you being confident to start pyro section optimization on the basis of this established mass and heat balance by yourself.

During day 1 and 2. We will provide you 9 lessons in the form of recorded videos for establishing detailed mass and heat balance of pyro section. With each lesson you will have an access to online calculator. So that you need not to hunt for excel templates to do mass and heat balance calculations.

In day 3, you will have to do assigned process measurements using portable instruments available. In case you do not have provision to do process measurements, at this time. Then I will provide you arbitrary measurements, so that you are able to practice writing a mass and heat balance of pyro section.

In day 4, You will do all mass and heat balance calculations using online calculators to calculate all material and heat streams, and finish the assignment of detailed mass and heat balance of your pyro section on the same day.

Moreover, we will meet online in Q&A session where I will be answering the questions about detailed mass and heat balance which you might have asked during day 1, 2, 3 and 4.

On day 5, we will provide you 3 more lessons to do a preliminary mass and heat balance from fuel, kiln feed, and clinker analysis with calculation method. Online calculators are available where you will have to just enter, fuel analysis, and other data, to calculate various material streams.

On day 6, you will be doing preliminary mass and heat balance of your pyro section, and you will have to submit the second assignment for progress evaluation.

On day 7, we will meet online in a grand webinar. Where, I will be answering first your questions you may have asked about preliminary mass and heat balance. And, Then we will discuss the detailed interpretation of mass and heat balance. And we will see! how we can calculate various key performance indicators from established mass and heat balance like gas velocities in preheater cyclones, residence time in calciner, combustion efficiency and false air analysis.

1. What is mass and heat balance!. as an activity, and as a tool?

2. What is detailed, and preliminary mass and heat balance?

3. Why should you do, mass and heat balance?

4. When should you do, mass and heat balance?

Day 0 will be analogous to a kickoff meeting to impart inertia to get mass and heat balance done within this one week’s time.

Remember! That it is not an online course where you have months together to study the subject. This is an action based workshop, where I will be working with you for the whole week’s time, and you have to dedicate this one week time as well for developing and doing mass and heat balance.

And at the end of this workshop I want to see you capable to write mass and heat balance of your pyro section. And you being confident to start pyro section optimization on the basis of this established mass and heat balance by yourself.

During day 1 and 2. We will provide you 9 lessons in the form of recorded videos for establishing detailed mass and heat balance of pyro section. With each lesson you will have an access to online calculator. So that you need not to hunt for excel templates to do mass and heat balance calculations.

In day 3, you will have to do assigned process measurements using portable instruments available. In case you do not have provision to do process measurements, at this time. Then I will provide you arbitrary measurements, so that you are able to practice writing a mass and heat balance of pyro section.

In day 4, You will do all mass and heat balance calculations using online calculators to calculate all material and heat streams, and finish the assignment of detailed mass and heat balance of your pyro section on the same day.

Moreover, we will meet online in Q&A session where I will be answering the questions about detailed mass and heat balance which you might have asked during day 1, 2, 3 and 4.

On day 5, we will provide you 3 more lessons to do a preliminary mass and heat balance from fuel, kiln feed, and clinker analysis with calculation method. Online calculators are available where you will have to just enter, fuel analysis, and other data, to calculate various material streams.

On day 6, you will be doing preliminary mass and heat balance of your pyro section, and you will have to submit the second assignment for progress evaluation.

On day 7, we will meet online in a grand webinar. Where, I will be answering first your questions you may have asked about preliminary mass and heat balance. And, Then we will discuss the detailed interpretation of mass and heat balance. And we will see! how we can calculate various key performance indicators from established mass and heat balance like gas velocities in preheater cyclones, residence time in calciner, combustion efficiency and false air analysis.

How long i will have access to learning material and online calculators?

You will be having access, for 15 days.

I am interested, but I am not an engineer! can i learn mass and heat balancing for process optimization in this workshop?

Yes! Absolutely you can, if you are interested! The learning material has been designed, and aligned in such a way, that you can easily do mass and heat balance just using elementary mathematical operations of addition, subtraction, and division only.

Remember that optimization is our responsibility. I cannot wait, till all of the cement plants have plenty of chemical engineers to understand process optimization. By going through our training courses, and workshops, you may not become as expert, as a process engineer can become. But, you can surely learn sufficient plant optimization skills to contribute in overall plant optimization process.

Remember that optimization is our responsibility. I cannot wait, till all of the cement plants have plenty of chemical engineers to understand process optimization. By going through our training courses, and workshops, you may not become as expert, as a process engineer can become. But, you can surely learn sufficient plant optimization skills to contribute in overall plant optimization process.

Can we get data sheets and tables for mass and heat balance?

You will be having access for 15 days. And all data sheets, and tables, which you need for mass and heat balance will be provided to you, and you can download them as well.