european cement research academy

Programme 2014 Seminars/Training course

www.ecra-online.org

Venues 2014 Retznei, Austria Aalborg, Denmark Duesseldorf, Germany Athens / Elefsina, Greece Wildegg, Switzerland

Photo: © Stefanie Grebe

4 Seminars 6 Training Course 7 Registration, Terms & Conditions 

Foreword European Cement Research Academy

Welcome to the European Cement Research Academy programme for 2014. This year ECRA is offering five seminars on the following topics:

 Alternative fuels: Quality and environmental control  Quality control of cement  CO2 monitoring and reporting: Latest developments and experiences in the cement industry  Refractory materials and high temperature corrosion in cement kilns  Hydration of blended cements In addition we are holding a two-and-a-half-day training course entitled  Clinker and cement production

Our venues are in Austria, Denmark, Germany, Greece and Switzerland. For further information and to register, please visit: www.ecra-online.org.

We look forward to seeing you!

Daniel Gauthier











Martin Schneider

Chairman of the Technical Advisory Board





Managing Director



Seminars 08 – 09 April 2014

20 May 2014

S14-01 Alternative Fuels: Quality and Environmental Control

S14-02 Quality Control of Cement

Objective: The seminar will provide a comprehensive overview of quality criteria and environmental control regarding the use of alternative fuels in the cement industry. Target group: Senior process engineers and experienced chemists dealing with the use of alternative fuels in general and specifically with aspects of quality control.

Objective: Overview of the requirements and modern techniques of quality control in cement plants. Target group: Quality managers, supervisors and personnel of cement plant laboratories

The environmentally safe and sound recovery of alternative materials has been taking place in the international cement industry for many years. On the one hand there is the necessity to substitute fossil fuels and natural raw materials with suitable alternative materials. On the other hand, the environmentally safe and sound operation of the process must be safeguarded. Moreover, the product quality as such has to be taken into account. The amount of alternative fuels has been continually increasing over the past years and maintaining quality surveillance for these materials is of great importance. The seminar will begin with an overview of the current European legislative requirements. In this context, the existing international standards will also be examined. Furthermore, the seminar will summarise how good product quality as well as a good environmental performance of the production process can be assured when alternative materials are used. Aspects of occupational health and safety will also be covered. The seminar includes a visit to the Lafarge cement plant in Retznei, Austria.

The requirements on cement put on the European market are laid down in European or national legislation and standards. However, additional requirements may arise for dedicated building applications. In order to fulfil these specifications, cement producers have to implement and operate a factory production control system which includes various physical and chemical test measures. This seminar will provide an overview of the typical requirements, in particular those defined in the relevant European standards, and of the procedures of quality control in cement plants. Common physical and chemical methods as well as modern techniques, e.g. Rietveld analysis, online and inline analysis will be discussed.

Presentations:  Legal requirements on the use of alternative fuels  Current standardisation activities regarding the use of alternative fuels  Examples of the application of suitable quality surveillance programmes for alternative fuels  Aspects of occupational health and safety regarding the use of alternative fuels  Optional new materials and their respective quality criteria  Future developments concerning the use of alternative fuels Venue: Retznei, Austria Nearest airport: Graz 

Presentations:  Overview of requirements: Construction Products Regulation, REACH, national regulations, European standards  FPC and Quality Management Systems acc. EN ISO 9001  Physical methods of quality control  Chemical methods of quality control  XRF, XRD and Rietveld analysis  Automation of quality control in cement plants; modern online and inline analysis

Venue: Duesseldorf, Germany Nearest airport: Duesseldorf International

Seminars 12 – 13 June 2014

24 – 25 September 2014

S14-03 CO2 Monitoring and Reporting: Latest Developments and Experiences in the Cement Industry

S14-04 Refractory Materials and High Temperature Corrosion in Cement Kilns

Objective: To provide experience of the application of different greenhouse gas monitoring and reporting approaches in the cement sector. The latest developments in monitoring methods and measurements will be presented and discussed. Target group: Senior CO2 and climate experts of cement companies, national and international associations, sustainability experts

Objective: Improved knowledge of condition analysis, material choice, wear phenomena and the installation technique of anchors and refractory materials in cement kilns and the preheater tower Target group: Process engineers, plant design engineers, refractory experts, maintenance engineers, plant managers, kiln engineers

The reporting of greenhouse gas (GHG) emission reductions and the accounting in emission trading schemes require specific monitoring and reporting (M&R) methods. Different international reporting systems co-exist. In the light of an international agreement on climate change or a sectorial approach, efficient procedures, their comparability and the verification of GHG emissions will become key elements. The seminar will give an overview of the existing M&R approaches and their application in the cement sector. Examples will include version 3.1 of the CO2 Protocol of the Cement Sustainability Initiative (CSI), the European Emissions Trading System (EU ETS, phase III) and reporting in the framework of CDM/JI projects. In addition, technical developments and current European standardisation works in the field of CO2 monitoring will be introduced. The seminar includes a visit to the Kamari plant of TITAN Cement in Elefsina, Greece.

The service life of refractory materials is an important cost factor in the clinker burning process. The lifetime of the refractory lining depends on a multitude of factors and above all on local stresses due to mechanical, thermal and chemical attack. In accordance with these stresses, suitable materials, types of lining and metallic anchors have to be selected. Depending on the fuels used and their chemical and physical condition, damage can occur as chemical attacks on bricks, linings and anchors. Because of the complex geometric shape of preheater and calciner systems and the flexible and rapid installation technique, nowadays monolithic refractory materials are mostly used. Besides the right choice of materials, the proper installation of the refractory affects the lifetime of the lining. To prevent damage during operation the condition of used refractory material must be correctly assessed during maintenance and winter outages. The seminar will give an overview of the relevant questions regarding current refractory technology and includes a visit to jura cement in Wildegg, Switzerland.

Presentations:  WBCSD CSI Cement CO2 and Energy Protocol (Experiences and updated version 3.1)  Experiences with the CSI Protocol from a company’s perspective (Case Studies)  Reporting requirements for CDM/JI projects  EU ETS: Phase III M&R requirements; CO2 verification experiences from 2014  Experiences with GHG monitoring, reporting and verification procedures in European cement companies (EU ETS)  CEN Standardisation Process on GHG Monitoring in Energy-Intensive Industries: Lessons from two plant tests; Quality control and uncertainty management  Technical Developments: Monitoring of CO2 stack emission / Measurements of biogenic carbon Venue: Athens/Elefsina, Greece Nearest airport: Athens International

Presentations:  New challenges and solutions for refractory materials inside the rotary kiln; Facing high usage of secondary fuels  The right choice of refractory material according to the position in the kiln system  State diagnosis techniques for refractory materials  High and low temperature corrosion in cement plants using high amounts of secondary fuels  Refractory wear phenomena: case study  State of the art: Monolithic refractory lining, bric lining  Safety during work on refractory materials Venue: Wildegg, Switzerland Nearest airport: Zurich 

Training Course

Seminars

14 – 16 October 2014

11 – 12 November 2014

T14-01 Clinker and Cement Production

S14-05 Hydration of Blended Cements

Objective: An introduction to clinker and cement manufacturing with a focus on raw material preparation, clinker burning and cement grinding. Target group: Recently recruited young engineers or foremen

Objective: Overview of the hydration reactions of supplementary cementitious materials (blended cements) Target group: R&D staff, quality managers

The training course will introduce new employees to the clinker burning process and grinding technology. A two-day in-depth training session will cover all relevant aspects of raw material preparation, clinker manufacturing and cement grinding. An additional focus will be placed on the possibilities of using different types of fuels. Case studies and laboratory experiments will illustrate the influence of fuel composition as well as burning and cooling conditions on clinker and cement properties. Environmental aspects of the clinker burning process will also be presented. The course includes a half-day visit to a cement plant.

The main driver of innovation in cement production in the coming years will be the pressure to reduce CO2 emissions and improve sustainability. One possibility to achieve this goal is the manufacture of cements with several main constituents (blended cements). For a successful implementation of these cements a broad knowledge of the hydration reactions of suitable main constituents themselves and in the cement matrix is important. Differences of the microstructure related to the cement type may need to be taken into account to ensure the durability of concretes manufactured with these cements.

Presentations:  Basics of cement and concrete  Introduction to the cement production process – Basics of materials – Raw materials and raw meal preparation – Clinker manufacturing process – Cement production and dispatch  Clinker burning process – Forming clinker – Material transformation – Fuels and combustion – Process technology of cement manufacturing (raw material drying, cyclone preheater, calciner, rotary kiln, clinker cooling) – State of the art rotary kiln burner – Co-firing of alternative fuels  Grinding technology – Raw material preparation; Grinding equipment – Raw material grinding – Cement grinding  Environmental aspects – Emission monitoring – Emission of gaseous compounds – Emission abatement technologies – Dust emission, dust abatement Venue: Duesseldorf, Germany Nearest airport: Duesseldorf International 

This seminar provides a deeper understanding of these mechanisms. The interaction of blended cements and concrete admixtures is also essential with regard to the wide use of these cements and will also be highlighted. The seminar will take place at the Aalborg Portland cement plant in Denmark.

Presentations:  Production of blended cements  Performance and hydration reactions of supplementary cementitious materials – Granulated blast furnace slag – Fly ash and ternary binder systems – Limestone – Calcined clays  Interaction of blended cements and concrete admixtures

Venue: Aalborg, Denmark Nearest airport: Aalborg

Registration, Terms & Conditions

Changes to ECRA Participation Fees For the last seven years ECRA has been able to keep its participation fees unchanged. We would like to inform you that due to rising costs our participation fee for seminars will be increased as from 2014 to 1,350 EUR per person. The participation fee for training courses will be increased to 1,900 EUR per person. There will continue to be a discount of 25 % for each additional participant from the same company address. Registration Registrations can only be made online via the ECRA website www.ecra-online.org. All current registration deadlines are shown on the website. Participants will receive written confirmation of their registration. Participation fee Unless stated otherwise, the participation fee per person for each seminar is 1,350 EUR for participants from ECRA member companies/organisations. The participation fee per person for the training courses is 1,900 EUR. The participation fee includes lectures, handouts, refreshments, lunch, evening dinner and, where necessary, group bus transfers to and from the nearest airport to the seminar venue. There is a discount of 25 % for each additional participant from the same company address. Cement associations which are ECRA members may delegate one participant to each event free of charge. Participants from companies or organisations which are not ECRA members will be charged double. VAT application: Invoices issued to recipients in Germany: The standard German rate of VAT, currently 19 %, will be applied. Invoices issued to recipients in other EU countries: VAT will not be applied if the recipient provides a valid VAT registration number (reverse charge rule according to Art. 196, 205 EU-Directive 2006/112). Invoices issued to recipients in non-EU countries: VAT will not be applied. A certificate of tax residence is required. The above-mentioned VAT application rules apply to the participation in ECRA seminars and training courses only.

Hotel accommodation Hotel accommodation is not included in the participation fee. ECRA will provide hotel recommendations, but participants must book their accommodation with the hotel directly themselves. In the event of the cancellation of a room reservation the terms and conditions of the hotel apply. Payment Participants will receive an invoice which is payable immediately upon receipt by bank transfer or cheque. Payment will be accepted in Euros only. Cancellations Participation fees will be refunded for cancellations made in writing up to seven days before a seminar / training course takes place. No refund will be made for cancellations received after this date. ECRA reserves the right to change the seminar programme and agendas and to cancel events in the case of insufficient bookings or other circumstances beyond its control. If an event is cancelled by ECRA, participants are entitled to a full refund of their participation fee. ECRA is not responsible for any other loss incurred by a participant as the result of the cancellation or amendment of an event by ECRA. The information in this programme is correct at the time of publication. These terms and conditions are governed by German law. For more information about ECRA and the latest news on all events please visit www.ecra-online.org.



Duesseldorf, December 2013

Contact: European Cement Research Academy GmbH Tannenstrasse 2 · 40476 Duesseldorf · Germany P.O. Box 30 03 32 · 40403 Duesseldorf · Germany Phone: Fax:

+ 49 (0) 211 23 98 38-0 + 49 (0) 211 23 98 38-500

E-Mail: Internet:

[email protected] www.ecra-online.org



european cement research academy