Heat-Recovery Systems and Waste-Heat Utilisation Training Course

Course Introduction

Heat recovery and waste-heat utilization have become essential strategies for improving industrial energy efficiency, reducing operating costs, and achieving sustainability goals across power generation, manufacturing, oil and gas, cement, steel, and chemical industries. The Heat-Recovery Systems and Waste-Heat Utilisation Training Course provides participants with comprehensive knowledge of heat recovery technologies, system design principles, operational practices, and maintenance strategies that maximize energy utilization while minimizing environmental impacts. The course equips professionals with practical skills to identify, evaluate, and implement effective heat recovery solutions across a wide range of industrial applications.

Participants will gain an in-depth understanding of various heat recovery systems including waste heat boilers, economizers, recuperators, regenerators, heat exchangers, heat recovery steam generators (HRSGs), thermal storage systems, condensate recovery systems, and cogeneration technologies. The training explains how these systems capture and reuse thermal energy that would otherwise be lost, improving plant efficiency, reducing fuel consumption, lowering emissions, and enhancing overall operational performance through integrated energy management practices.

The course emphasizes practical approaches to system operation, performance monitoring, preventive maintenance, predictive maintenance, troubleshooting, and reliability improvement. Participants will learn methods for evaluating heat recovery performance, optimizing thermal efficiency, minimizing heat losses, diagnosing equipment failures, and implementing maintenance programs that increase equipment reliability, extend service life, and reduce operational downtime. Real-world engineering examples and case studies reinforce the application of these concepts in industrial environments.

Emerging technologies are transforming heat recovery and energy management practices, and this course explores innovations such as Industrial Internet of Things (IIoT), artificial intelligence, digital twins, smart energy management systems, predictive analytics, advanced heat exchanger materials, thermal energy storage, and industrial decarbonization technologies. Participants will understand how digital monitoring, automation, and intelligent control systems improve equipment performance, optimize energy recovery, and support sustainable industrial operations while meeting increasingly stringent environmental regulations.

Throughout the training, participants will examine practical industrial case studies, engineering calculations, system optimization projects, and equipment performance evaluations that strengthen technical understanding and decision-making capabilities. Interactive discussions focus on identifying waste heat sources, selecting appropriate recovery technologies, evaluating project feasibility, improving return on investment, and implementing best engineering practices that maximize energy efficiency and operational reliability across industrial facilities.

Upon successful completion of the course, participants will possess the technical knowledge and practical skills required to design, operate, inspect, maintain, troubleshoot, and optimize heat recovery systems and waste-heat utilization technologies. They will be equipped to contribute effectively to energy efficiency initiatives, plant modernization projects, sustainability programs, carbon reduction strategies, and long-term asset management plans that improve industrial competitiveness and environmental performance.

Duration

5 days

Who Should Attend

• Mechanical Engineers

• Energy Engineers

• Thermal Engineers

• Process Engineers

• Power Plant Engineers

• Plant Operations Engineers

• Maintenance Engineers

• Reliability Engineers

• Utility Engineers

• Energy Managers

• Industrial Facility Managers

• HVAC Engineers

• Project Engineers

• Sustainability Managers

• Environmental Engineers

• Process Improvement Specialists

• EPC Contractors

• Technical Consultants

• Asset Management Professionals

• Engineering Supervisors

Course Objectives

• Develop a comprehensive understanding of heat recovery technologies, waste-heat utilization principles, and industrial energy efficiency strategies for sustainable operations.

• Understand the design, operation, and performance characteristics of heat exchangers, economizers, recuperators, regenerators, waste heat boilers, and HRSG systems.

• Identify waste heat sources across industrial processes and evaluate suitable heat recovery technologies based on technical, operational, and economic considerations.

• Apply engineering principles to optimize thermal efficiency, minimize heat losses, improve fuel utilization, and enhance overall plant energy performance.

• Implement preventive, predictive, and reliability-centered maintenance practices that improve equipment availability, extend service life, and reduce maintenance costs.

• Perform system performance monitoring, thermal analysis, energy audits, and condition assessments using modern engineering tools and industry best practices.

• Analyze operational problems using structured troubleshooting and root cause analysis techniques to improve system reliability and process efficiency.

• Understand international energy efficiency standards, environmental regulations, safety requirements, and quality management practices applicable to heat recovery systems.

• Explore emerging technologies including Industrial Internet of Things, artificial intelligence, digital twins, smart energy management systems, and advanced thermal storage solutions.

• Strengthen decision-making capabilities for heat recovery project planning, lifecycle asset management, equipment modernization, carbon reduction, and sustainable industrial development.

Comprehensive Course Outline

Module 1: Fundamentals of Heat Recovery and Waste-Heat Utilisation

• Principles of industrial heat recovery and thermal energy conservation

• Identification of waste heat sources across industrial operations

• Energy efficiency concepts and thermal performance fundamentals

• International standards and best practices for heat recovery systems

Module 2: Heat Recovery Equipment and Technologies

• Design and operation of shell-and-tube and plate heat exchangers

• Waste heat boilers, economizers, recuperators, and regenerators

• Heat Recovery Steam Generator systems and industrial applications

• Thermal energy storage technologies and integrated recovery systems

Module 3: Heat Exchanger Design and Performance

• Heat transfer mechanisms and equipment selection methodologies

• Fouling mechanisms, thermal resistance, and cleaning strategies

• Performance testing, thermal balancing, and efficiency optimization

• Mechanical integrity assessment and lifecycle performance evaluation

Module 4: Waste-Heat Recovery Applications

• Heat recovery in power generation and combined cycle facilities

• Industrial applications within cement, steel, and petrochemical plants

• Waste heat utilization in manufacturing and process industries

• Cogeneration and combined heat and power integration strategies

Module 5: System Operation and Performance Optimization

• Operational control strategies for efficient heat recovery systems

• Monitoring thermal performance using engineering performance indicators

• Process integration for maximizing energy recovery opportunities

• Optimization methods for reducing fuel consumption and emissions

Module 6: Maintenance and Reliability Management

• Preventive maintenance planning for heat recovery equipment

• Predictive maintenance using condition monitoring technologies

• Inspection techniques for heat exchangers and thermal systems

• Reliability-centered maintenance for critical energy recovery assets

Module 7: Troubleshooting and Failure Analysis

• Root cause analysis for heat recovery equipment failures

• Diagnosing heat exchanger fouling, corrosion, and leakage problems

• Corrective maintenance planning and equipment restoration methods

• Performance improvement through continuous operational assessment

Module 8: Safety, Environmental, and Regulatory Compliance

• Safety procedures for operating thermal and pressure systems

• Environmental compliance and industrial emissions reduction strategies

• Occupational health and risk management in heat recovery facilities

• Engineering documentation, inspections, and quality assurance practices

Module 9: Emerging Technologies and Smart Energy Systems

• Industrial Internet of Things for thermal system monitoring

• Artificial intelligence and predictive analytics for energy optimization

• Digital twins for heat recovery system simulation and maintenance

• Advanced materials and decarbonization technologies for energy efficiency

Module 10: Asset Management and Sustainable Energy Strategies

• Lifecycle management of heat recovery and thermal equipment

• Economic evaluation and return on investment for recovery projects

• Energy management systems and continuous efficiency improvement

• Developing integrated waste-heat utilization and sustainability roadmaps

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: training@upskilldevelopment.com Tel: +254 721 331 808

Training Venue 

The training will be held at our Upskill Training Centre. We also offer training for a group (at a discount of 10% to 50%) at requested location all over the world. The Onsite course fee covers the course tuition, training materials, two break refreshments, buffet lunch, airport transfers, Upskill gift package, and guided tour.

Visa application, travel expenses, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Upskill certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: training@upskilldevelopment.com, +254 721 331 808

Terms of Payment:

Unless otherwise agreed between the two parties’ payment of the course fee should be done 3 working days before commencement of the training so as to enable us to prepare better.