COURSE OVERVIEW:

The meaning of integrated industrial plant energy optimization strategies refers to the holistic coordination of all energy-consuming assets and process flows within a facility to achieve a state of maximum thermal and electrical synergy. This course focuses on breaking down "utility silos," where steam, power, and process cooling are traditionally managed in isolation. By applying "Systems Thinking," plant engineers can identify cross-functional opportunities where the waste of one process becomes the high-value input of another, leading to radical improvements in the overall Energy Performance Indicator (EnPI).

The scope of this training covers the synchronization of demand-side and supply-side energy management, focusing on "Total Site Integration." It examines the technicalities of "Cogeneration" and "Trigeneration," where the simultaneous production of power, heat, and cooling maximizes fuel utilization. The course provides a deep dive into advanced control logic, specifically "Model Predictive Control" (MPC), which anticipates process disturbances and adjusts utility loads in real-time to prevent energy "spikes" and inefficient idling.

Coverage includes the analysis of "Industrial Symbiosis," where energy and resource loops extend beyond the plant walls into neighboring facilities. The course addresses the critical role of storage—both thermal and electrical—in balancing the intermittency of integrated renewable sources. Participants will gain practical expertise in utilizing "Energy Mapping" tools, conducting plant-wide "Exergy" audits, and formulating strategic investment roadmaps that prioritize projects with the highest systemic impact on plant-wide profitability and carbon neutrality.

COURSE OBJECTIVES:

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

1.  Apply "Systems Thinking" to identify cross-departmental energy synergies.

2.  Conduct a "Total Site Heat Integration" audit using Pinch principles.

3.  Optimize the balance between on-site Cogeneration and grid power.

4.  Implement "Model Predictive Control" (MPC) for plant-wide utility management.

5.  Synchronize "Steam-Electric" demand to minimize venting and throttling.

6.  Design "Energy Cascades" where waste heat is reused at descending temperatures.

7.  Integrate Large-Scale Thermal Energy Storage (TES) for load shifting.

8.  Evaluate the benefits of "Industrial Symbiosis" and shared utility networks.

9.  Utilize "Digital Twins" to simulate the impact of process changes on energy.

10.  Conduct an "Exergy Analysis" to identify the "True" locations of waste.

11.  Manage the integration of variable on-site renewables with process demand.

12.  Formulate a multi-year master plan for an "Integrated Energy Plant."

TARGET AUDIENCE:

This course is designed for Industrial Plant Directors, Utility Engineers, Energy Strategists, Process Optimization Specialists, and Lead Energy Auditors working in complex, multi-utility industrial environments.

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.