COURSE OVERVIEW:

The meaning of industrial energy conservation refers to the proactive and systematic application of advanced engineering, digital control, and process optimization to reduce the energy required to manufacture goods. This course focuses on moving beyond basic "housekeeping" measures to address the fundamental energy intensity of industrial operations, which often represent the largest cost and carbon footprint for an organization. By integrating high-efficiency hardware with sophisticated data analytics, industrial facilities can achieve substantial gains in competitiveness and environmental compliance.

The scope of this training encompasses the optimization of core industrial utilities—steam, compressed air, and pumping—alongside the implementation of transformative technologies like industrial heat pumps and waste-to-energy recovery. It examines the technicalities of "Process Intensification," where radical changes in chemical or mechanical pathways lead to massive energy savings. The course provides a deep dive into the "Industry 4.0" paradigm, utilizing the Industrial Internet of Things (IIoT) and Artificial Intelligence (AI) to create self-optimizing energy loops.

Coverage includes the analysis of "Specific Energy Consumption" (SEC) and the implementation of ISO 50001 management systems to ensure conservation is a continuous process rather than a one-time event. The course addresses the critical role of behavioral change and the "Energy Culture" within the workforce. Participants will gain practical expertise in performing cross-functional energy audits, calculating the marginal abatement cost of conservation projects, and formulating technical roadmaps for the complete decarbonization of industrial sites.

COURSE OBJECTIVES:

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

1.  Identify and quantify the primary energy sinks in industrial manufacturing.

2.  Calculate the "Specific Energy Consumption" (SEC) for different product lines.

3.  Apply "Pinch Analysis" to optimize heat exchange and minimize utility use.

4.  Implement advanced waste heat recovery using Organic Rankine Cycles (ORC).

5.  Evaluate the efficiency of high-temperature industrial heat pumps.

6.  Optimize the energy performance of cross-functional motor-driven systems.

7.  Conduct "Process Integration" to synchronize thermal and electrical demand.

8.  Utilize IIoT and real-time dashboards for industrial energy monitoring.

9.  Assess the ROI of transitioning from thermal to electrical process heating.

10.  Design and implement a "Kaizen" program for continuous energy improvement.

11.  Navigate the requirements of the ISO 50001:2018 Energy Management Standard.

12.  Formulate a technical business case for "Deep Decarbonization" of industrial assets.

TARGET AUDIENCE:

This course is designed for Plant Managers, Energy Managers, Process Engineers, Operations Directors, Maintenance Leads, and Sustainability Officers in the chemical, food and beverage, cement, and 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.