COURSE OVERVIEW:

The meaning of operational energy efficiency in oil, gas, and petrochemical plants refers to the systematic application of engineering principles and real-time process monitoring to maximize the throughput of refined products while minimizing the specific energy input. This course focuses on the highly energy-intensive nature of hydrocarbon processing, where minor improvements in thermal or mechanical efficiency can translate into significant financial savings and carbon footprint reductions. By moving beyond design-phase calculations, this program teaches operators how to maintain peak efficiency under varying feedstocks and fluctuating market demands.

The scope of this training encompasses the entire downstream and midstream value chain, including distillation units, hydrotreaters, and catalytic crackers. It examines the technicalities of fuel-gas management, heat integration within complex process units, and the optimization of auxiliary utilities such as high-pressure steam and cooling water loops. The course provides a deep dive into the utilization of advanced process control and digital twins to identify energy "drift" and provide actionable insights for process adjustments that stabilize energy intensity.

Coverage includes the analysis of flare gas recovery, the implementation of high-efficiency furnace combustion, and the reduction of parasitic electrical loads in massive pumping and compression stations. The course addresses the critical role of energy benchmarking, utilizing international standards to compare plant performance against global peers. Participants will gain practical expertise in conducting site-wide energy audits, formulating decarbonization strategies for chemical clusters, and developing technical business cases for the adoption of low-carbon hydrogen and electrification technologies.

COURSE OBJECTIVES:

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

1.  Analyze the fundamental energy intensity drivers within petrochemical process units.

2.  Evaluate the thermodynamic efficiency of crude distillation and fractionation columns.

3.  Optimize furnace combustion air-to-fuel ratios to reduce fuel gas consumption.

4.  Implement flare gas recovery systems to capture and repurpose waste hydrocarbons.

5.  Quantify the impact of catalyst deactivation on process energy requirements.

6.  Design heat integration schemes to maximize energy recovery between process streams.

7.  Manage the energy efficiency of large-scale steam methane reforming (SMR) units.

8.  Utilize advanced process control (APC) to minimize energy variance during transients.

9.  Conduct energy audits specific to oil and gas facilities using ISO 50001 frameworks.

10.  Identify opportunities for the electrification of steam-driven prime movers.

11.  Minimize energy losses in high-pressure gas transport and storage infrastructure.

12.  Formulate a comprehensive energy efficiency roadmap for a petrochemical complex.

TARGET AUDIENCE:

This course is designed for Process Engineers, Plant Managers, Operations Supervisors, Energy Coordinators, and Technical Leads working in refineries, gas processing plants, and petrochemical manufacturing facilities.

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.