Furnaces Operation & Optimization Course - Safe Use

Overview
Course Outline
Scheduled Dates

Course Overview

Furnace operations are critical in industrial processes such as refining, chemical, and petrochemical plants. Safe and efficient furnace operation requires a deep understanding of combustion processes, heat transfer, and the essential steps in furnace start-up and shutdown. This course focuses on optimizing furnace performance while maintaining safety standards. Participants will gain insights into combustion phenomena, troubleshooting, and the implementation of best practices for furnace operation.

Objective:

To describe industrial combustion phenomena and calculate the air/fuel ratio for optimum combustion.
To identify bad-quality combustion from flue gas analysis and flame study, and implement corrective steps.
To list and apply the main steps of a furnace start-up procedure.
To recognize the main operating and material constraints for an optimal, safe and reliable furnace operation.

Course Outline

Day 1: Furnace Construction and Operating Conditions

Introduction to different types of furnaces and their functions in industrial processes.
Key operating conditions and their impact on heat distribution and efficiency.
Estimation rules and parameters affecting furnace efficiency and ways to improve it.
Construction details of heat exchange areas and the use of refractory materials, including tube bundle arrangements and insulation types.

Day 2: Combustion and Burners

Understanding combustion conditions: stoichiometric air/fuel ratio, heating values, and fuel characteristics.
Overview of burner operations: fuel and air supply, functionality, and low NOx burner characteristics.
Analysing combustion quality through flue gas oxygen levels and unburned material.
Combustion safety, flame detection, and safety devices on fuel circuits.
Understanding air and flue gas circulation systems: natural and forced draft, pressure differential control, and safety devices.

Day 3: Heat Transfer and Tube Coil

Principles of heat transfer to the tube bundle: conduction, convection, and radiation, and the factors governing heat transfer.
Understanding tube skin temperature, tube temperatures, and the effects of fouling.
Dividing heated fluids into several passes and managing flow rate safety systems.
Furnace temperature constraints: skin temperature, bridge-wall temperature, and risks of exceeding limits.

Day 4: Furnace Operation

Monitoring combustion and heating during on-stream furnace operations and modifying operating conditions.
Analysing disturbances and key points for maintaining safe furnace operation.
Understanding safe ignition procedures and handling shutdowns, including emergencies.
Identifying and troubleshooting furnace incidents, such as explosive atmospheres and tube ruptures.

Day 5: Furnace Start-up, Shutdown, and Safety

Comprehensive review of the furnace start-up procedure: preparation, ignition, and post-shutdown ignition.
Safe shutdown procedures, including standard and emergency shutdown processes.
Incident management: diagnosing and addressing issues like unbalanced heat and furnace malfunctions.
Application of furnace temperature profile and heat recovery distribution, understanding the relationship between fuel burned and combustion air excess.

Schedule & Fees

3 For 2Offer

Get the most out of group training with our special discount! Register 3 of your participants together on the same course and only pay for 2.

Select Month

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December

Location

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London

London

$5,900

Duration: 5 Days

date: 15 - 19 Dec 2025

Chemical Engineering

Furnaces: Safe Operation and Optimization

Duration:5 Days

date:15 - 19 Dec 2025

London

$5,900

CPD Standards

Employees of professional or formally regulated bodies are generally expected to have CPD accredited training. This type of accreditation ensures that the training is knowledgeable, informed and constantly updated. It ensures our standards as a company are kept high and consistent.

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