Day-to-Day Energy Optimization for Industrial Plants


Who should attend?

  • This course aims to optimize energy consumption and operational costs by improving operation of thermal equipment and steam network balance.
Public :
  • Operation, technical staff & supervisors involved in the technology and operation of thermal equipment, and interested in energy consumption optimization of the plant.

Level :Skilled

Prerequisite :
  • Engineer diploma or equivalent experience in process industry.

Course Content


      • 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).

      • 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.
      • Applications and 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.

      • 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.

      • 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.

      • 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.
      • Impact of a lack of thermal insulation.

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,
  • set the operating conditions and the right tunings for combustion optimization in furnaces and boilers,
  • provide opportunities for improving energy balances.

Ways & Means

  • Practical course and case studies based on industrial feedbacks.
  • Numerous exercises to improve understandings.
To French entities : IFP Training is referenced to DataDock ; you may contact your OPCO about potential funding.
Please contact our disabled persons referent to check the accessibility of this training program :