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Day-to-Day Energy Optimization for Industrial Plants

Day-to-Day Energy Optimization for Industrial Plants

5 days
EMT/MENERG-E
Sessions
This course is not scheduled.
Who should attend?

Audience

    • Operation, technical staff & supervisors involved in the technology and operation of thermal equipment, and interested in energy consumption optimization of the plant.

Level

  • Proficiency
  • This course aims to optimize energy consumption and operational costs by improving operation of thermal equipment and steam network balance.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • list the key points of production and propose an economic use of steam and electricity,
  • identify the source of main pollutants and ways of reducing emissions,
  • set the operating conditions and the right tunings for combustion optimization in furnaces and boilers,
  • provide opportunities for improving energy balances.
Course Content

ENERGY BALANCE - EFFICIENCY & CONTEXT

0.5 day

  • KPI’s definition (Key Performance Indicators): energy intensity and efficiency, units and use.
  • Motivations and constraints: energy dependence and regulation.
  • Different approaches for energy efficiency: operation improvement, operating conditions optimization, significant improvement solutions, Best Available Techniques (BAT).

ENERGY CONSUMPTION INSIDE FURNACES & BOILERS

1 day

  • Main type of furnaces and boilers. Operating conditions.
  • Heat balance, efficiency estimate. Scope and limitations to improve efficiency.
  • Material and equipment used to improve efficiency and heat recovery.
  • Pollutants and techniques to reduce emissions. Low-NOx Burners.
  • Applications & exercises:
  • Heater efficiency estimate and flue gas composition calculation.
  • Boiler operating conditions analysis - Heat recovery in radiant and convection zone.
  • Impact of fuel composition on atmospheric emissions.

ELECTRICITY & STEAM PRODUCTION

1.5 days

  • Cogeneration cycles: boiler-steam turbine, gas turbine-waste heat boiler.
  • Operating conditions (extraction or discharge pressure, single recovery or post-combustion waste heat boiler’s operation) and thermal performance.
  • Steam network operation and balance. Mechanical energy produced by steam expansion, energy recovery and electricity production optimization.
  • Sources of margin: technology and use of steam traps.
  • Application:
  • Study of a power plant.
  • Estimation of production cost for steam (HP, MP, LP) and electricity.

HEAT & MECHANICAL ENERGY RECOVERY

1.5 days

  • Scope and limitations of heat recovery inside heat exchangers. Parameters impacting heat flux and heat transfer.
  • Sources of margin: heat exchangers performance follow-up, impact of fouling, cleaning strategy and optimum cleaning frequency calculation.
  • Low temperature heat recovery: heat pumps solutions or mechanical compression of gases (main operating constraints).
  • Mechanical energy recovery inside process-gas turbines.
  • Application:
  • Heat exchanger train performance follow-up.
  • Optimum cleaning frequency calculation.

PROCESS OPERATION

0.5 day

  • Limitation of losses: mechanical (operating conditions) and thermal (insulation).
  • Ways to reduce energy consumption by adjusting operating conditions (pressure, recycle gas flowrate…), thermal integration.
  • Applications:
  • Study of different flow control system on compressor.
  • Impact of a distillation column operating parameters on energy consumption.
Ways & Means
  • Practical course & case studies based on industrial feedbacks.
  • Numerous exercises to improve understandings.