Process Plant Optimization, Revamping and Debottlenecking

Why Select this Training Course?

Making process plants work their best involves managing maintenance and equipment effectively and ensuring the plant runs reliably and lasts long. Energy management and cutting down energy use are crucial for optimising process plants. Introducing modern controls and new technologies can boost these opportunities even more, leading to better plant optimisation. This Rcademy Process Plant Optimisation, Revamping, and Debottlenecking course focuses on the aspect of controlling and managing process plant operations. In this program, participants will learn how to do this effectively in a way that will enable the process to run at its most efficient best. This will be done while ensuring efficient and sound working practices necessary for the operation of the plant.

The primary objective of a revamp is to enhance simple factors such as a plant’s rate or capacity. That is why debottlenecking and revamping need flexibility in planning and pertinent expertise in using the appropriate engineering instruments.

The Rcademy Process Plant Optimisation, Revamping, and Debottlenecking training course will help participants understand the methodology or steps to be adopted to enhance off-site plants and their entities, such as plant design, storage facilities, and inventory. They will also learn more about utility management and optimisation, revamping process plants, and debottlenecking.

What does debottlenecking mean?

Debottlenecking is a strategy that involves increasing the throughput of processes and equipment by remodelling them. Debottlenecking is the identification of the production constraints and taking them to a level where production capacity is no longer a constraint.

What are the objectives of plant optimisation?

Plant optimisation is the act of ensuring that a plant has the highest productivity possible. Optimising a plant’s efficiency involves a myriad of factors, such as facility energy and labour consumption, and implementing the most efficient procedures regarding those factors. The goal is to get the highest yield of the final product with the lowest possible input of raw materials. This involves assessing what is currently in place and ensuring that the plant has the appropriate raw materials and is being utilised appropriately.

Who Should Attend?

The Rcademy Process Plant Optimisation, Revamping and Debottlenecking would suit various professionals working on process plants specialising in the petrochemical and refinery industry. The program would be suitable for:

• Process plant technical professionals with a technical background in process engineering and plant operating as well as optimisation skills.
• Plant engineers, technologists, and operators involved in the actual running, care, and preservation of process plants.
• Managers and technicians who are in a position to coordinate plant activities, enforce safety measures, and perform upkeep duties.
• Project engineers specialising in planning for revamping and debottlenecking projects in process plants and designing and executing those plans.
• Engineers and technicians who need to enhance the efficiency of processes and petrochemical plants and the profitability of refineries.
• Those who are involved in planning, managing, and ensuring energy efficiency. 

What are the Course Objectives?

After completing the Rcademy Process Plant Optimisation, Revamping and Debottlenecking training program effectively, participants will be able to:

• Understand plant optimisation and energy conservation in detail.
• Explain and apply the managerial skills that would help in the proper management of a plant with regards to productivity and efficiency.
• Analyse the effectiveness of capacity creep and explain the approaches to cost-efficient debottlenecking.
• Adopt structured approaches for plant reliability improvements such as Cause Analysis, Logic Diagrams, Fault Tree Analysis, etc.
• Discuss the function and relevance of management and enterprise information systems in plants for optimisation.
• Develop an understanding of risks associated with the optimisation of process plants.
• Evaluate the maintenance, energy, utilities, environmental, and safety aspects when revamping and debottlenecking.
• Examine the economic factors, planning, and other factors related to project management.

How will this Course be Presented?

This course is designed with participants in mind, focusing on meeting their expectations and helping them learn and grow. Several practical methods were employed to ensure active learning throughout the course. Experienced professionals teach the course, bringing their years of expertise to the table. The course content is based on thorough research, ensuring it’s relevant and comprehensive.

In the Rcademy Process Plant Optimisation, Revamping, and Debottlenecking Course, participants will get a mix of practical and theoretical learning materials, including slides, lecture notes, case studies, videos, and real-life scenarios. Participants will also take part in quizzes, seminars, and practice sessions to reinforce their learning. The platform also values feedback and strives to ensure your satisfaction through a dedicated feedback platform.

What are the Topics Covered in this Course? 

Module 1: Introduction to Process Plant Operation

• Understanding optimisation technologies for process plants
• Essential components of process plant optimisation
• Constraints in optimisation
  • Production
  • Operation
  • Economy
  • Environment
• Exploring optimisation approaches
• Utilising mathematical and physical models
• Interconnection between process optimisation and control
• Workshop: examples and resolutions

Module 2: Fundamentals of Process Plant Optimisation

• Basics of process plant optimisation and control
• Essential elements of process optimisation
• Key components for industrial process optimisation
• Building mathematical models for processes
• Understanding process variables
• Utilising simulation technology for plant control
• Fundamentals of heat integration

Module 3: Energy Management for Business and Environment

• Industrial energy management practices
• Promoting energy efficiency in business and environmental context
• Energy utilisation in process industries
• Overview of energy management standards
• Features and challenges of energy management programs

Module 4: Strategies for Energy Conservation

• Global standards and benchmarking guidelines
• Effective practices in process plant energy management
• Checklist for energy conservation in industrial plants
• Identifying energy conservation opportunities
• Conducting energy audits: types and methods
• Benchmarking energy consumption and intensity
• Assessing new energy-efficient technologies
• Evaluating renewable energy from technical and economic perspectives

Module 5: Implementation of Plant Optimisation Activities

• Impact of plant optimisation on operations
• Implementing technological modifications in plants
• Licensing of new technologies
• Considerations for human resources
• Promoting safety for operational excellence
• Understanding the costs of safety incidents

Module 6: Identifying and Analysing Plant Bottlenecks

• Definition and types of bottlenecks
• Impact on plant performance
• Techniques for identifying bottlenecks
  • Process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs)
  • Data collection and analysis
  • Process simulations and modelling

Module 7: Strategies for Revamping and Debottlenecking

• Exploring revamping strategies
• Enhancing production capacity
• Addressing maintenance, energy, utilities, environmental, and safety concerns
• Considering economic, planning, and project management aspects
• Case studies
  • Optimising a polypropylene plant
  • Debottlenecking ethylene & propylene plant
  • Revamping an oil refinery plant

Module 8: Advanced Techniques and Tools for Optimisation

• Process simulation and modelling
  • Software tools (e.g., Aspen HYSYS, CHEMCAD, PRO/II)
  • Case studies and practical applications
• Process integration and pinch analysis
  • Heat integration and energy savings
  • Case studies on energy optimisation
• Advanced control strategies
  • Model predictive control (MPC)
  • Real-time optimisation (RTO)

Module 9: Monitoring and Continuous Improvement

• Performance monitoring
  • Key performance indicators (KPIs)
  • Online monitoring tools and techniques
• Data analytics and machine learning
  • Predictive maintenance and anomaly detection
  • Case studies on data-driven optimisation
• Continuous improvement programs
  • Lean manufacturing and Six Sigma
  • Implementation of continuous improvement initiatives

Module 10: New and Advanced Trends

• Advanced Process Control (APC)
• Modularisation and prefabrication
• Industry 4.0: data analytics, AI, IoT, Machine Learning
• Flexible and modular design
• Simulation and optimisation of processes
• Agile PM application
• Digital technologies and remote operation
• Integration of renewable feedstocks
• Circular economy initiatives
• Remote monitoring and control