Introduction

Heat exchangers are critical components in modern process engineering, thermal systems, HVAC, oil & gas, chemical processing, power generation, and renewable energy systems, enabling efficient heat transfer, energy recovery, and process optimization. Heat Exchanger Design and Optimization Training Course provides a comprehensive, industry-focused understanding of thermal design principles, rating and sizing methods, fouling analysis, pressure drop optimization, and performance enhancement techniques using both classical correlations and modern simulation tools.

With increasing demand for energy efficiency, carbon reduction, digital twins, and sustainable engineering solutions, optimized heat exchanger systems play a vital role in reducing operational costs and improving plant reliability. This course integrates advanced heat transfer theory, TEMA standards, CFD simulation insights, and real-world industrial case studies to equip participants with practical skills in designing, troubleshooting, and optimizing heat exchangers for maximum thermal performance and minimum energy loss.

Programme Curriculum

Heat Exchanger Design and Optimization Training Course

Introduction

Course Duration

5 days

Course Objectives

Master fundamentals of convective & conductive heat transfer mechanisms
Apply LMTD and ε-NTU methods for exchanger analysis
Design shell-and-tube heat exchangers using TEMA standards
Optimize performance using thermal-hydraulic balancing techniques
Analyze and reduce fouling, scaling, and corrosion effects
Perform pressure drop calculations and flow optimization
Improve efficiency using energy recovery systems
Understand CFD-based heat exchanger simulation basics
Evaluate performance using effectiveness and NTU optimization
Apply pinch analysis for process integration
Select materials for high-temperature and corrosive environments
Implement troubleshooting techniques for industrial failures
Develop skills in digital twin-based thermal system optimization

Target Audience

Process Engineers
Mechanical Engineers
Chemical Engineers
HVAC Engineers
Energy & Sustainability Consultants
Plant Maintenance Engineers
Design Engineers in EPC companies
Graduate Engineering Students

Course Modules

Module 1: Fundamentals of Heat Transfer & Thermodynamics

Modes of heat transfer: conduction, convection, radiation
Governing equations for thermal systems
Heat exchanger classification
Temperature profiles and driving forces
Case Study: Industrial boiler heat loss reduction analysis

Module 2: Heat Exchanger Types & Industrial Applications

Shell & tube, plate, finned, double pipe exchangers
Selection criteria for industries
Material considerations
Operational limitations
Case Study: Petrochemical plant shell-and-tube selection optimization

Module 3: Thermal Design Methods

LMTD method application
ε-NTU effectiveness method
Correction factors
Design constraints
Case Study: HVAC system cooling coil performance improvement

Module 4: Hydraulic Design & Pressure Drop Analysis

Flow regimes and Reynolds number impact
Pressure drop estimation
Pumping power requirements
Tube-side vs shell-side balancing
Case Study: Refinery exchanger pressure drop reduction project

Module 5: Fouling, Corrosion & Maintenance Optimization

Types of fouling mechanisms
Scaling prevention techniques
Corrosion-resistant materials
Cleaning strategies
Case Study: Power plant fouling mitigation success story

Module 6: Heat Exchanger Network Optimization

Pinch analysis fundamentals
Energy integration strategies
Waste heat recovery systems
Process intensification concepts
Case Study: Cement industry waste heat recovery system design

Module 7: Advanced Simulation & CFD Applications

Introduction to CFD modeling
Thermal simulation setup
Mesh generation basics
Performance validation
Case Study: CFD-based plate heat exchanger efficiency enhancement

Module 8: Industrial Troubleshooting & Digital Optimization

Failure mode analysis
Performance degradation diagnostics
Retrofit and revamp strategies
Digital twin applications
Case Study: LNG plant exchanger efficiency restoration project

Training Methodology

This course employs a participatory and hands-on approach to ensure practical learning, including:

Interactive lectures and presentations.
Group discussions and brainstorming sessions.
Hands-on exercises using real-world datasets.
Role-playing and scenario-based simulations.
Analysis of case studies to bridge theory and practice.
Peer-to-peer learning and networking.
Expert-led Q&A sessions.
Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@fineskilltrainingcenter.org or call +254769199797

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to Fineskill Training Center account, as indicated in the invoice so as to enable us prepare better for you.

Skills & Software Covered

Thermal analysis Heat transfer efficiency Design calculations Performance optimization

Programme Fee

Duration: 5 Days

Method: Online or Physical

Online Price: $1,000

Physical Price: $1,500

Certification: Accredited Certificate

View Available Dates 📄 Download Course Outline (PDF)

Available Sessions

Location

Month

Year

Oct 26 2026

26 Oct — 30 Oct 2026

💻 Online / Virtual session

Online $1,000