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Process Plant Optimisation & Energy Conservation 13th – 17th January 2025 (Weekdays)

This five-day course will provide a turbo-machinery package operator and maintenance technician with the knowledge and skills necessary to operate ... Show more
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The Process Plant Optimization & Energy Conservation course focuses on enhancing the efficiency and productivity of industrial plants while reducing energy consumption and operating costs. This course is beneficial for professionals in the chemical, petrochemical, power generation, and other process-intensive industries. . It aims to equip participants with the knowledge and skills required to optimize their plant operations while minimizing energy consumption and environmental impact.

 

Course Objectives:

 

1. Understand Process Optimization:

Gain knowledge about the principles and methods for optimizing various process parameters.

Learn how to use analytical tools for process data analysis and identify bottlenecks in operations.

 

2. Enhance Energy Efficiency:

Identify opportunities for energy conservation in industrial plants.

Understand how to implement best practices for energy management and energy-efficient technologies.

 

3. Improve Plant Performance:

Learn techniques for improving production rates, yield, and quality through optimization.

Gain the ability to minimize waste and enhance overall operational efficiency.

 

4. Economic Analysis of Process Improvements:

Learn how to evaluate the cost-benefit analysis of optimization projects.

Understand investment and operational costs related to energy-saving initiatives.

 

5. Develop Practical Skills in Process Monitoring:

Learn how to monitor, control, and adjust key process variables to maintain optimal operation.

Understand the use of advanced software and instrumentation for process control.

 

6. Sustainability and Environmental Impact: 

Focus on reducing emissions and environmental footprint through energy conservation.

Understand regulatory requirements and compliance regarding energy use and emissions.

 

 

Course Contents:

1. Introduction to Process Optimization:

Definition and importance of process optimization in industrial plants.

Key concepts like efficiency, productivity, and yield.

Overview of different optimization techniques.

 

 

2. Energy Management Principles:

Introduction to energy auditing and energy management systems (EMS).

Understanding energy flows in process industries.

Key performance indicators (KPIs) for energy use.

 

 

3. Process Modeling and Simulation:

Basics of process modeling and the role of simulations in optimization.

Use of simulation tools for process analysis (e.g., Aspen Plus, HYSYS).

Developing process models for optimization studies.

 

4. Advanced Control Strategies for Optimization:

Overview of control systems and their role in optimization (PID, DCS, and SCADA).

Model Predictive Control (MPC) and its application in process plants.

Real-time optimization techniques for plant control.

 

5. Heat Integration and Energy Conservation:

Heat exchanger network (HEN) design and optimization.Pinch analysis for energy efficiency.

Techniques for minimizing heat losses and improving heat recovery.

 

6. Process Equipment Optimization:

Optimizing pumps, compressors, heat exchangers, and other equipment for energy savings.

Maintenance practices that contribute to energy efficiency.

Monitoring and improving equipment performance.

 

7. Steam Systems and Boiler Optimization:

Energy conservation in steam generation and distribution.

Optimizing boiler efficiency through combustion control and feedwater management.

Steam traps, condensate recovery, and their role in energy savings.

 

8. Compressed Air and Utility System Optimization:

Improving efficiency in compressed air systems.

Best practices for cooling water and refrigeration systems.

Managing utilities like nitrogen and oxygen for cost savings.

 

9. Economic Evaluation of Optimization Projects:

Tools for assessing the financial viability of optimization projects.

 Payback period, Net Present Value (NPV), and Internal Rate of Return (IRR) calculations.

 Case studies on cost-benefit analysis for energy conservation projects.

 

10. Case Studies and Practical Applications:

Real-world examples of successful process optimization and energy conservation.

Group exercises to apply optimization techniques in simulated scenarios.

Analysis of optimization projects with a focus on lessons learned.

 

11. Sustainability and Environmental Regulations:

Role of energy conservation in reducing carbon emissions.

Compliance with environmental standards (ISO 50001, local regulations).

Strategies for implementing sustainable practices in process plants.

 

12. Future Trends in Process Optimization:

Digital transformation and Industry 4.0 in process optimization.

Role of artificial intelligence and machine learning in predictive maintenance and process optimization.

Emerging technologies for energy conservation.

 

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Course details
Duration 10 hours
Video 9 hours
Level Advanced

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