Plant Supervisors CEO, MD &

Management Committee

Researchers Postgraduate Students

Date: 31 July – 2 August 2018 (User Level) 25 – 26 September 2018 (Advanced Level)

Venue: Universiti Teknologi Malaysia, Johor Bahru

Maximise Utility Cost Savings, Minimise Emissions Using Pinch Analysis

Organised by :

What are the minimum heating/cooling needs (energy targets) of a process?

What is the scope for minimising energy, water and emissions?

What is the economic mix of utilities (LP, MP, HP steam, fuel, water) in a

plant?

What are the steps and options to reduce utilities without requiring

investment?

What is the scope for maximising energy savings via cogeneration in a

facility?

What are the practical steps in energy, water and emission reduction

projects?

How to maximise utility savings with minimum changes to the existing plant?

How to design or improve a process to minimise energy, water and

emissions?

A Practical Approach to Minimise Energy, Cost and Emission in

Process Industry

Process integration using pinch analysis provides facility and site planners,

plant designers and process engineers with practical knowledge, skills and

step-wise method for the integrated optimal planning, design and retrofit

processes, facilities and manufacturing sites to promote industrial symbiosis

and achieve the triple-bottom line benefits of minimised utilities (e.g. thermal

energy from fuel, electricity, water), minimised costs (operating, maintenance

and investment costs) and minimised wastes (including CO2, gaseous

emissions, water).

A Proven Technique Abroad, experiences of multinational petrochemical corporations like Shell,

Exxon, BP, Dow, Mitsubishi, JGC and Union Carbide in Europe, USA and Japan

have shown that Pinch Analysis has led to utility savings in the range of 15 –

95%, and capital savings of up to 30%. Locally, the potential for pinch

application is tremendous. Results from feasibility studies conducted on a

number of local process plants point towards substantial scope for savings as

shown below:

Project Project Type Annual Hot Utility Savings (Utility Type)

Annual Cold Utility Savings (Utility Type)

Estimated Payback Period on Investment

Crude Oil Refinery Retrofit of Heat Exchanger

17% (Steam) 22% (Cooling Water)

2 years

Palm Oil Refinery Retrofit of Heat Exchanger and Reduction of Fouling

65% (Steam) 48% (Cooling Water)

6 months

Oleochemical (Fatty Alcohol Fractionation)

Process Modifications & Heat Exchanger Network Retrofit

43% (Steam) 89% (Cooling Water)

4.5 months

Semi-Conductor Reuse/Recycle and Process Modifications

72.4% (Fresh Water)

82.4% (Waste Water)

12 months

Aromatics Plant

Heat Exchanger Network Redesign (New Design)

60% (Steam) 20% (Cooling Water)

2 additional heat exchangers required

Gas Processing Plant

Heat Exchanger Network Retrofit

12% (Steam) 15.6% (Refrigeration)

1.25 years

“In the light of Pinch Analysis development, process plants should consider, retrofit beyond energy audit”. (Maintenance Manager, Palm Oleo) “I personally appreciate the practical case studies and work sessions and the software/ programme developed by PROSPECT of UTM (Utility Engineer, Petronas Gas Berhad) “A very useful tool to redesign or troubleshoot heat exchanger/ water network to save utility cost” (Energy Audit Engineer, GreenTech Malaysia) “An efficient technique for analysis and reduction of utilities leading to significant savings” (Senior Process Engineer, Riau Pulp and Paper Mill) “I am impressed on the power of pinch for energy and utility reductions” (Process Engineer, Shell Middle Distillate Synthesis)

MODULE 1: User Level

Overview of Pinch Analysis as a Tool to Maximise Utility Savings in Process Industry

Process Integration – The Basic Concepts Setting the Minimum Utility Targets Design of Heat Exchanger Network Stream Data Extraction (SDE) Multiple Utilities Combined Heat and Power (CHP) Process Modifications (PM) Optimal Heat Computer Demo Setting Targets, Heat Recovery Design and Improvement

Using Optimal heat

MODULE 2: Advanced Level

Introduction to Pinch Analysis Step-wise retrofit procedure Stream Data extraction for heat recovery Review of Energy Targeting for Maximum Heat Recovery Total Site Heat Integration and Combined Heat and Power Operating and Capital Cost Calculations Application of Pinch Retrofit Method on Refinery Case

Study

CO

UR

SE

MO

DU

LE

INTR

OD

UC

TIO

N

Plant Managers Utility Managers Process Designers /

Engineers Process Technologists University Lecturers

TE

STIM

ON

Y P

AR

TIC

IPA

NTS

Up to 300 companies

outreached!

CO

UR

SE

OB

JEC

TIV

ES

WHO SHOULD ATTEND

Game-Changing Questions Addressed by Pinch Analysis:

Complimentary Pinch Software

Real-life Industrial Case

Studies

Maximising Energy Cost Savings in Industry Using Pinch Analysis (Plant Design Stage) – 3-Day User Level

Maximising Energy Cost Savings in Industry Using Pinch Analysis (Retrofit Stage) – 2-Day Advanced Level

COURSE TUTORS

Shell Refinery BP – Amoco MLNG Felda Proctor and Gamble MIMOS Semiconductor Riau Pulp and Paper Mill Qatar LNG Pertamina Engineering Group PT Titan Petrokimia Interindo Pan Century Oleochemicals BASF – Petronas

AMONG THE COMPANIES THAT HAVE BENEFITED FROM OUR PINCH COURSE

Prof Ir Dr Zainuddin A. Manan CEng, FIChemE, REEM, CEM is a professor of chemical engineering, the founding director of

UTM Process Systems Engineering Centre (PROSPECT), the founding Dean of the UTM Faculty of Chemical and Energy Engineering

and the founder of Optimal Systems Engineering, a UTM spin-off company. He began his career as an engineer in PETRONAS and

Hume Industries and has been an academic leader, educator, researcher, consultant and professional coach for 25 years. He has

completed over 100 R & D & consultancy projects, and has over 450 publications (patents/copyrights, 15 books/chapters; 200

refereed journals; 220 proceedings) on sustainable engineering of resources (energy, power, water, emissions & materials). Zain is

a UK/EU chartered engineer, a Fellow IChemE, a professional engineer, a certified energy manager, a registered electrical energy

manager and a certified trainer for ASEAN energy managers. He has delivered over 400 invited talks in workshops, seminars and

conferences across the world and coached professionals from over 500 national/multi-national organisations. Zain founded and

spearheaded the UTM Sustainable Energy Management initiative that led UTM to achieve more than USD 5 million energy savings

between 2011 and 2016, and to win the ASEAN Energy Award in 2012.

Online Registration:

http://www.prospect.utm.my/register-pinch-analysis

Course Fee:

RM 2499 per module

RM 4000 for 2 modules

* 50% discount for student (ID required) ** A group of 5 persons, get 20% discount

Prof Ir Dr Sharifah Rafidah Wan Alwi is the Director of Process Systems Engineering Centre of Universiti Teknologi Malaysia (UTM). Sharifah has been extensively involved in 60 research projects (worth RM4.995Million), 23 industrial based projects for various companies and government agencies and has trained engineers from more than 200 companies in the field of sustainable engineering design and management. She specialises in process systems engineering with emphasis on resource conservation. She has won numerous awards such as Green Talents 2009, IChemE Highly Commended Sir Frederick Warner Prize 2011, ASEAN Young Scientist and Technologist Award 2014, National Young Scientist Award 2015, Runner-up for ASEAN-US Science Prize for Women 2016 and Malaysia Rising Star 2016. She is one of the active committee for UTM Living Lab - Sustainable Energy Management Systems which has won the 3 Star AEMAS Energy Management Gold Standard and the ASEAN Energy Award 2012. She also serves as the Chairman for Malaysia IChemE Young Engineer Group (YEG) and is a member of Young Scientist Network, Academy of Sciences Malaysia (YSN-ASM) and Persatuan Saintis Muslim Malaysia (PERINTIS). She is a certified ASEAN Energy Management Scheme (AEMAS) Energy Manager trainer and a Registered Electrical Energy Manager under Malaysia Energy Commissioner.

Dr Lim Jeng Shiun is currently the Products and Services Manager of Process Systems Engineering Centre (PROSPECT), Univesiti

Teknologi Malaysia. His core expertise is in the area of the innovative development and application of process systems engineering techniques for resource conservation, and for energy and carbon planning. Dr Lim is a certified country expert of “Thermal Energy Efficiency and Solar Heat Integration into Process” and “Steam System Optimisation” under UNIDO. He is also a chartered engineer under IChemE, a professionally Certified Energy Manager, and a Registered Electrical Energy Manager certified by Energy Commissions of Malaysia. As an engineer in practice, he has applied the output of his research work in consultancy projects for the industrial community. He has been extensively involved in 22 research projects, 11 industrial based projects for various companies and government agencies. The key clients include local industries and multinational companies such as BERNAS, FABER MEDISERVE, SHELL, OLEON in Malaysia and PERTAMINA in Indonesia. He has assisted those companies identify energy saving opportunities worth millions of dollar through the use of process integration and process systems engineering approach.

MTBE (Petronas) Huntsman Tioxide Malaysia Newsprint Industries Malaysia Palm Oil Board Suruhanjaya Tenaga Technip (M) Sdn Bhd Amoco Mitsui PTA PT Chandra Asri Petronas Penapisan (M) Sdn Petronas Gas Sdn Bhd UKM, UPM, USM, UM, MICET

CPD Hours

Claimable

Up to

80% discount

HRDF-Claimable

For more details, please contact:

Mrs. Amira / Mrs. Huda Process Systems Engineering Centre (PROSPECT), N29, Faculty of Chemical & Energy Engineering,

Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Johor Website: http://www.prospect.utm.my

Tel: +607-553 6244/016-716 7248; Fax: +607-558 8166

Email: training.prospect@utm.my