COURSE OVERVIEW:

Heat integration and pinch analysis represent the most sophisticated methodologies for enhancing energy efficiency within industrial chemical processes. This course provides a rigorous technical framework for analyzing the heat flows within a process plant to identify the "Pinch Point," which defines the fundamental thermodynamic limit for heat recovery. Participants will learn how to construct Composite Curves and Grand Composite Curves to visualize energy targets and determine the minimum hot and cold utility requirements for any given system.

The scope of this training involves the systematic design of Heat Exchanger Networks (HEN) that minimize external fuel consumption and cooling water usage. Attendees will explore the "Golden Rules" of pinch technology, learning how to avoid inappropriate heat transfers across the pinch that lead to energy penalties. The course details the use of the Grid Diagram for network synthesis, teaching engineers how to match hot and cold streams based on temperature driving forces and heat capacity flow rates to achieve maximum energy recovery (MER).

Coverage includes the practical application of pinch analysis in both grassroots designs and existing plant retrofits. Participants will examine the integration of complex utility systems, including steam headers, heat pumps, and combined heat and power (CHP) units, with the process heat demand. By focusing on the economic trade-offs between capital investment in heat transfer area and long-term energy savings, this course equips process engineers with the analytical depth to significantly reduce the carbon footprint and operating costs of refinery and petrochemical facilities.

COURSE OBJECTIVES:

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

1.  Explain the fundamental laws of thermodynamics governing heat integration.

2.  Construct and interpret Hot and Cold Composite Curves for complex processes.

3.  Identify the Process Pinch Point and explain its physical significance.

4.  Calculate the Minimum Hot Utility and Minimum Cold Utility targets.

5.  Apply the "Above the Pinch" and "Below the Pinch" design heuristics.

6.  Synthesize Heat Exchanger Networks (HEN) using the Grid Diagram method.

7.  Utilize the Grand Composite Curve to select appropriate utility levels.

8.  Evaluate the impact of Delta T Minimum on capital and operating costs.

9.  Perform a "Pinch Violation" analysis to identify energy waste in existing plants.

10.  Optimize the integration of distillation columns and reactors within the HEN.

11.  Design cost-effective retrofits for heat exchanger networks with area constraints.

12.  Assess the benefits of Heat Pump integration and Cogeneration systems.

13.  Formulate a strategic energy master plan for a multi-unit industrial site.

TARGET AUDIENCE:

Process Engineers, Energy Managers, Design Engineers, and Sustainability Coordinators involved in process optimization and utility management.

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.