A browser-based cement control room simulator with real process physics, a hard safety gate and an AI kiln-burner coach. Operators practice the expensive moments before they happen. Every shift, no install.
Veteran burners retire with the pattern recognition that prevents rings, red rivers and coal mill fires.
You cannot schedule a ring collapse. Operators meet their first one live, at 3 a.m.
Four-day seminars mean travel and a few seats a year. Custom simulators mean projects, installs and instructors.
A real upset from the plant answer key: coating collapse, reducing calciner, coal mill CO, power dip.
ISA-101 gray mimic, live trends, ISA-18.2 alarms. Move 14 levers, start and stop drives, radio the field.
Real lags, noise, interlocks and overshoot. Chase noise and it oscillates. Ignore it and it escalates.
Break a hard rule, like firing with no draft or opening a smoldering coal mill, and the drill is an F. Full stop.
Scored replay, answer key, AI coach debrief, handover note, XP, rank and a training record.
In our September 2026 market scan we found no cement training offering that combines these five capabilities. Each incumbent does one or two of them well.
A deterministic pyro-line model runs in the browser: heat and air balance, lags, interlocks. No DCS link, no OT network exposure, no IT ticket.
Seven hard rules from the plant safety doctrine cap any violation at F, however good the numbers looked. A justified shutdown earns full marks.
ISA-101 gray graphics with color only for abnormal states, ISA-18.2 alarm priorities, flashing unacked alarms, shelving and flood counts.
Every drill ends with a personal debrief that cites the operator's own moves and times, plus Socratic hints mid-drill and handover feedback.
Readiness matrix per operator and drill, certificate checklist, CSV training records that support task-training documentation.
Plant profiles scale capacity, fuel mix, alternative fuel share, preheater stages and bypass. Tailoring adds your tags, setpoints and incidents.
| On-the-job mentoring | Seminar with simulator | Custom plant simulator | Generic process OTS | CCR Academy |
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● yes ◐ partial or package-dependent ○ no. Based on public vendor materials reviewed September 2026 (for example Fuller CEMulator seminars, KHD SIMULEX, AVEVA, Honeywell and Yokogawa OTS). Capabilities vary by package; custom simulator project cost is a McKervey Solutions estimate.
Every drill, run two ways on the reference plant: the textbook response from the answer key, and no response at all.
Illustrative model with conservative defaults. Replace with plant data. Not a guarantee of results.
Annual subscription. No hardware, no install, no DCS connection. For comparison: sending four operators to a four-day seminar runs about $18,000 with travel.
Prove it on one kiln line.
Everything a crew needs, every shift.
Your kiln, your tags, your incidents. + $15,000 one-time tailoring
One standard across every plant.
Operators and instructors invited. Everyone runs an Easy drill in the first session.
Every operator completes the seven safety-critical drills. The readiness matrix shows where each crew stands.
Tailored plant profile, tags and first custom drills built from your incident history.
Before and after scores by crew and area, safety gate trends and time-to-first-action improvements.
No connection to the plant DCS or OT network. The simulator is training only and reinforces site SOPs, lockout/tagout and permits.
Scores, records and handover notes live in your workspace database and export as CSV at any time.
Drills, bands and hard rules come from a written process model, scenario answer key and safety doctrine your experts can review.
Start a 90-day pilot on one kiln line. Fully credited to year one.
CCR Academy is built by McKervey Solutions.