COURSE OVERVIEW:

Debottlenecking is the strategic process of identifying and removing constraints in existing process units to increase production capacity and improve profitability. This course provides a technical and systematic framework for evaluating the latent potential of refinery and petrochemical assets without the need for massive capital investment. Participants will explore the engineering methodologies required to analyze the hydraulic, thermal, and kinetic limits of individual pieces of equipment and the unit as a whole.

The scope of this training involves a multi-disciplinary approach, integrating process simulation with mechanical rating and operational data analysis. Attendees will learn how to identify "pinch points" in distillation columns, heat exchangers, compressors, and piping networks. The course emphasizes the use of high-fidelity models to predict the impact of increased flow rates or changed feedstocks on product quality and equipment integrity, providing a roadmap for technical feasibility studies.

Coverage includes the evaluation of various debottlenecking strategies, from simple control logic adjustments to internal hardware retrofits like high-capacity trays or structured packing. Participants will examine the economic evaluation of debottlenecking projects, including the calculation of return on investment (ROI) and payback periods. By mastering these optimization techniques, engineers and technical managers will be equipped to squeeze maximum value from existing assets while maintaining safety margins and environmental compliance.

COURSE OBJECTIVES:

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

1.  Define the systematic workflow for a process debottlenecking study.

2.  Identify physical and process constraints using plant data and simulations.

3.  Perform hydraulic ratings for distillation columns and vessel internals.

4.  Evaluate the capacity limits of heat exchangers and pre-heat trains.

5.  Analyze the performance of pumps and compressors for increased throughput.

6.  Assess the impact of debottlenecking on utility systems like steam and power.

7.  Use sensitivity analysis to identify the primary "bottleneck" in a complex unit.

8.  Compare the benefits of hardware retrofits versus process parameter changes.

9.  Evaluate the impact of higher throughput on catalyst life and reactor kinetics.

10.  Identify piping and control valve limitations in high-flow scenarios.

11.  Conduct a safety and relief system re-evaluation for increased capacities.

12.  Calculate the economic viability and ROI of proposed debottlenecking projects.

13.  Formulate a comprehensive debottlenecking report with technical recommendations.

TARGET AUDIENCE:

Process Engineers, Project Engineers, Production Managers, and Technical Consultants involved in asset optimization and plant expansion.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.