Introduction

Process Flow Sheet Design is a critical discipline in chemical engineering, process engineering, plant design, and industrial optimization, forming the backbone of efficient, safe, and cost-effective production systems. Process Flow Sheet Design Training Course equips learners with advanced competencies in process simulation, PFD development, P&ID fundamentals, mass and energy balance, equipment integration, and process optimization strategies. It is designed to align with modern industry demands in oil & gas, petrochemicals, pharmaceuticals, renewable energy, hydrogen economy, and sustainable process design, where digital engineering and AI-assisted process modeling are rapidly transforming traditional workflows.

This training emphasizes hands-on mastery of process flow diagram development, Aspen HYSYS/Plus simulation concepts, pinch analysis, unit operations integration, debottlenecking, and process safety considerations (HAZOP-ready design thinking). Participants will gain the ability to translate conceptual process ideas into fully optimized engineering flow sheets that improve plant efficiency, CAPEX/OPEX reduction, carbon footprint minimization, and operational reliability. The course bridges theory with real-world engineering applications using industry case studies and simulation-driven design scenarios.

Programme Curriculum

Process Flow Sheet Design Training Course

Introduction

Course Duration

5 days

Course Objectives

Master Process Flow Diagram (PFD) development using industry standards
Understand mass balance and energy balance optimization techniques
Apply process simulation tools
Design efficient unit operations integration systems
Develop competency in process equipment selection and sizing
Improve plant efficiency through debottlenecking strategies
Apply Pinch Analysis for heat integration and energy optimization
Strengthen understanding of process safety and HAZOP-ready design logic
Implement sustainable process engineering and green design principles
Enhance skills in process optimization and cost reduction
Build expertise in P&ID interpretation and development fundamentals
Learn digital twin concepts in process engineering workflows
Apply industry case-driven decision-making for real plant design scenarios

Target Audience

Chemical Engineers and Process Engineers
Mechanical Engineers in plant design roles
Oil & Gas industry professionals
Petrochemical plant operators and designers
Pharmaceutical manufacturing engineers
Energy and renewable process engineers
Final-year engineering students
Technical consultants and EPC contractors

Course Modules

Module 1: Fundamentals of Process Flow Sheet Design

Process design lifecycle and engineering workflow
PFD vs P&ID differentiation and applications
Standard engineering symbols and conventions
Process documentation structure
Case Study: Crude oil stabilization unit flow sheet

Module 2: Mass and Energy Balance Applications

Steady-state and dynamic balance systems
Component and overall material balance
Energy integration fundamentals
Process efficiency calculations
Case Study: Ethanol production plant balance model

Module 3: Process Simulation Fundamentals

Introduction to simulation environments
Thermodynamic property packages
Flow sheet building logic
Sensitivity analysis basics
Case Study: Natural gas sweetening simulation

Module 4: Unit Operations Integration

Reactors, separators, heat exchangers integration
Process configuration selection
Equipment interaction effects
Scale-up considerations
Case Study: Ammonia synthesis loop optimization

Module 5: Heat Integration & Pinch Analysis

Energy recovery systems design
Hot and cold stream analysis
Minimum energy requirement calculations
Utility system optimization
Case Study: Refinery heat exchanger network redesign

Module 6: Process Safety & Risk-Based Design

Inherent safety principles
HAZOP methodology integration
Relief systems and safety valves
Risk mitigation design strategies
Case Study: LNG plant safety flow redesign

Module 7: Process Optimization & Debottlenecking

Plant capacity enhancement techniques
Bottleneck identification tools
Optimization algorithms overview
Cost-performance trade-offs
Case Study: Petrochemical plant capacity expansion

Module 8: Sustainable & Digital Process Engineering

Green engineering principles
Carbon footprint reduction strategies
Digital twin in process systems
AI-assisted process design concepts
Case Study: Hydrogen production plant optimization

Training Methodology

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

Process design Flow optimization Equipment selection Mass balance analysis

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

Nov 02 2026

02 Nov — 06 Nov 2026

💻 Online / Virtual session

Online $1,000