Optimizing Process Plants and Conserving Energy

Introduction:

Optimizing process plants relies heavily on maintaining plant integrity and reliability. To reap the benefits of such optimizations, it is crucial to minimize downtime caused by equipment and system degradation. Effective inspection and maintenance policies are necessary to sustain these benefits. Plant optimization not only offers economic advantages but also helps avoid the significant costs associated with constructing new plants.

By managing energy-consuming systems—such as steam, cooling water, process heating, and electric motors—organizations can achieve considerable cost reductions. Further enhancements can be made through process modifications like advanced controls, new catalysts, and innovative technologies. This course, "Optimizing Process Plants and Conserving Energy," focuses on process plant optimization as a fundamental aspect of increasing profitability and operational effectiveness.

Objectives:

Upon completion of this Optimizing Process Plants and Conserving Energy course, participants will be able to:

• Understand plant optimization and energy conservation—its purpose, benefits, and implementation strategies.
• Enhance the profitability of plants by refining marketing aspects of the strategy.
• Identify key areas for energy savings.
• Utilize managerial tools to improve plant configurations.
• Implement methods and techniques for technical and economic evaluations of alternatives.
• Grasp the essential elements of plant optimization.
• Maximize plant availability, reliability, and productivity.
• Reduce operational costs.

Training Methodology:

• Case Studies
• Workshops
• Simulations
• Group Discussions
• Role Playing
• Interactive Exercises
• Scenario Analysis
• Project-Based Learning

Course Outline:

Unit 1: Process Plant Operation, Integrity, and Reliability

• Principles of process plant optimization and energy saving.
• Resource management related to facilities operation, inspection, and maintenance.
• Interdependence of plant integrity and reliability from both physical and operational perspectives.
• Importance of operation and maintenance in ensuring plant integrity and reliability.
• Equipment condition monitoring and evaluation.
• Formation of Operating Windows (OW) for maximizing throughput.
• Implementation of Effective Management of Change (MOC) program.
• Economics of process plants.

Unit 2: Process Plant Optimization

• Basic concepts of process control.
• Targeted elements within a process plant for improvement.
• Components for industrial process improvement.
• Controlled process variables and process characteristics.
• Foundations of thermal coupling and pinch technology.
• PragmaEngineering for heat exchanger networks optimization.
• Optimization procedures and simulation technology for plant optimization.

Unit 3: Industrial Energy Management - Energy Efficiency: Good for Business, Good for Environment

• Energy use and optimization in process industries.
• Energy management methods and standards.
• Energy conservation programs in the industry.
• Best energy management methodologies for process plants.
• Development of energy management strategies and addressing unique challenges.
• Examples of energy management tools and programs.
• Energy appraisal incentives and energy-saving design projects.

Unit 4: Energy Management Scheme Implementation

• Operating energy management systems.
• Assessing energy intensity and patterns.
• Evaluating technology options for new energy conservation systems.
• Energy-conserving measures for organizational processes.
• Market feasibility analysis of potential opportunities.

Unit 5: Consequences of Activities Aimed at Plant Optimization

• Treating energy efficiency as a business resource.
• Link between optimization activities and technological changes.
• Impact on plant operating and safety conditions.
• Technology know-how and financing instruments.
• Influence on manpower factors.