Process Plant Optimization, Revamping, and Debottlenecking 1st – 5th September, 2025

Course Overview

This 5-day specialised training program is designed to equip professionals with the knowledge and skills required to optimise the performance of process plants. The course focuses on techniques to improve operational efficiency, enhance throughput, and maximise profitability while minimising capital expenditures. Participants will gain expertise in identifying and addressing bottlenecks, evaluating equipment performance, and implementing cost-effective process modifications. Additionally, the course covers strategies for revamping ageing systems, incorporating advanced technologies, and improving energy efficiency. Through a combination of theoretical concepts, data-driven methods, and real-world case studies, this program provides a comprehensive framework for achieving operational excellence in process plants.

Course Objectives

By the end of this course, participants will be able to:

1. Identify and analyse operational bottlenecks affecting plant performance.

2. Develop and implement optimisation strategies to improve process efficiency.

3. Plan and execute revamping projects to upgrade outdated systems and integrate new technologies.

4. Enhance energy efficiency and minimise operational costs.

5. Apply data analysis techniques to evaluate equipment performance and process conditions.

6. Utilise debottlenecking methods to increase plant capacity without major capital investment.

Target Audience

• Process engineers and plant operators.

• Maintenance and reliability professionals.

• Project managers involved in plant revamping projects.

• Technical and operational managers in process industries.

• Engineering consultants and designers.

• Professionals aiming to improve plant performance and efficiency.

Daily Agenda

Day One: Fundamentals of Process Plant Optimisation

• Introduction to Plant Optimisation: Objectives and benefits.

• Process Performance Metrics: Key performance indicators for evaluating plant efficiency.

• Data Analysis in Optimisation: Tools and techniques for process evaluation.

• Identifying Bottlenecks: Methods for diagnosing inefficiencies in plant systems.

• Case Study: Analysis of plant performance data for optimisation opportunities.

Day Two: Techniques for Process Optimisation

• Optimising Unit Operations: Strategies for refining distillation, reaction, and separation processes.

• Energy Optimisation in Process Plants: Heat integration and waste energy recovery techniques.

• Advanced Control Systems: The role of automation and predictive control in optimisation.

• Maximising Throughput: Strategies to align production capacity with market demands.

• Workshop: Process simulation for optimisation scenarios.

Day Three: Revamping Aging Process Systems

• Introduction to Plant Revamping: Goals and planning considerations.

• Modernising Equipment and Technologies: Selecting and integrating advanced systems.

• Evaluating Revamping Projects: Economic analysis and risk assessment.

• Project Execution Strategies: Minimising downtime during revamping activities.

• Case Study: Successful revamping projects in process industries.

Day Four: Debottlenecking Strategies

• Understanding Debottlenecking: Objectives and approaches.

• Process Modifications: Enhancing capacity through incremental changes.

• Equipment Upgrades and Retrofits: Addressing hardware limitations.

• Operational Adjustments: Streamlining workflows to minimise constraints.

• Hands-on Exercise: Debottlenecking a simulated process plant.

Day Five: Continuous Improvement and Practical Applications

• Sustaining Optimisation Efforts: Establishing a culture of continuous improvement.

• Monitoring and Controlling Optimised Processes: Real-time performance tracking.

• Regulatory Compliance and Safety: Adhering to standards during optimisation and revamping.

• Cost-Benefit Analysis for Optimisation Projects: Justifying investment decisions.

• Final Assessment: Troubleshooting and optimisation strategy development.

• Wrap-Up Discussion: Lessons learned and actionable insights.

Why Choose this Course?

This course provides a practical, industry-focused framework for optimising, revamping, and debottlenecking process plants. Participants will gain actionable insights into improving efficiency, increasing capacity, and reducing costs without major capital investments. By incorporating cutting-edge techniques and real-world applications, the program equips professionals with the skills needed to drive continuous improvement and achieve operational excellence.

Learning Outcomes

Upon completion of the course, participants will:

1. Be adept at diagnosing and addressing process inefficiencies.

2. Understand and implement strategies for optimising plant operations and energy usage.

3. Plan and manage revamping projects to upgrade process systems.

4. Apply debottlenecking techniques to enhance plant capacity.

5. Develop a sustainable approach to continuous improvement in process plant operations.