COURSE OVERVIEW:

The meaning of energy efficiency optimization for industrial heaters and furnaces refers to the systematic engineering and operational improvements aimed at maximizing thermal transfer while minimizing fuel consumption and emissions. This course focuses on the most energy-intensive components of the process industry—fired heaters, boilers, and kilns—and how to address the significant heat losses typically associated with combustion, radiation, and flue gas discharge. By understanding the complex interplay between flame geometry, draft control, and refractory health, operators can achieve double-digit fuel savings and extend the lifespan of these critical assets.

The scope of this training covers a wide array of furnace types, including cabin, cylindrical, and box heaters used in refining and chemical processing. It examines the technicalities of high-efficiency burner design, including Low-NOx and ultra-low-NOx variants, and the application of automated oxygen trim systems to maintain optimal air-to-fuel ratios. The course provides a deep dive into advanced heat recovery technologies, such as air preheaters and waste heat boilers, alongside the use of high-emissivity ceramic coatings that enhance radiant heat transfer within the furnace box.

Coverage includes rigorous thermal auditing techniques using infrared thermography and flue gas analysis to identify "hidden" energy leaks. The course addresses the critical safety and environmental regulations governing furnace operations, including draft management to prevent "positive pressure" hazards and the reduction of greenhouse gas emissions. Participants will gain practical expertise in developing predictive maintenance programs focused on tube decoking and refractory repair, providing a robust framework for managing high-temperature process equipment sustainably and cost-effectively.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Calculate the thermal efficiency of fired heaters using the heat loss method.
2. Optimize combustion by managing excess air, draft, and fuel-air mixing.
3. Evaluate the benefits of high-emissivity ceramic coatings for refractory surfaces.
4. Design and implement flue gas heat recovery systems (Air Preheaters and Economizers).
5. Identify and mitigate localized tube overheating and "hot spots" using thermography.
6. Assess the impact of tube-side fouling and coking on energy consumption.
7. Implement advanced draft control strategies (Natural vs. Forced vs. Induced).
8. Select and maintain high-efficiency, low-emission burner technologies.
9. Conduct a detailed thermal balance for complex multi-zone furnaces.
10. Navigate the safety protocols for furnace startup, shutdown, and emergency venting.
11. Minimize radiation and convection losses through optimized insulation.
12. Formulate a technical business case for a furnace efficiency retrofit project.

TARGET AUDIENCE:

This course is designed for Process Engineers, Maintenance Engineers, Furnace Operators, Energy Auditors, and Technical Supervisors in the oil refining, petrochemical, steel, and glass manufacturing industries.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.