Introduction

Waste Heat Recovery Systems (WHRS) are transforming modern industrial energy management by enabling the capture and reuse of thermal energy that would otherwise be lost to the environment. In today’s era of decarbonization, energy efficiency optimization, and sustainable industrial engineering, WHRS plays a critical role in reducing fuel consumption, lowering greenhouse gas emissions, and improving overall process efficiency across sectors such as power plants, cement, steel, oil & gas, and manufacturing.

Waste Heat Recovery Systems Training Course is designed to equip participants with advanced knowledge of thermal energy recovery technologies, ORC systems, heat exchangers, economizers, and industrial heat integration strategies. The course blends theory with real-world industrial applications, enabling learners to design, evaluate, and optimize WHR systems for maximum energy savings and ESG compliance.

Programme Curriculum

Waste Heat Recovery Systems Training Course

Introduction

Course Duration

5 days

Course Objectives

Understand fundamentals of waste heat recovery technologies and energy balance systems
Analyze industrial processes for energy efficiency optimization
Evaluate different WHR systems including economizers, recuperators, regenerators
Design basic heat exchanger networks (HEN) for industrial applications
Understand Organic Rankine Cycle (ORC) and steam recovery systems
Identify heat loss sources in cement, steel, refinery, and power plants
Apply carbon footprint reduction strategies using WHR solutions
Develop skills in thermal system performance assessment
Learn integration of WHR into Industry 4.0 smart energy systems
Conduct feasibility studies for industrial energy recovery projects
Optimize fuel consumption using process heat integration techniques
Understand global standards for energy management (ISO 50001)
Build capability in sustainable engineering and net-zero transition strategies

Target Audience

Energy engineers and process engineers
Mechanical and thermal engineers
Plant managers and operations supervisors
Sustainability and ESG consultants
Industrial maintenance engineers
Power plant technicians and engineers
Oil & gas refinery professionals
Engineering students specializing in energy systems

Course Modules

Module 1: Fundamentals of Waste Heat Recovery

Basics of thermal energy and heat transfer
Sources of industrial waste heat
Heat loss mechanisms in industries
WHR system classifications
Energy audit fundamentals
Case Study: Heat loss mapping in a cement manufacturing plant

Module 2: Heat Exchanger Technologies

Types of heat exchangers
Heat transfer efficiency improvement methods
Fouling and maintenance issues
Thermal performance evaluation
Material selection for high temperature systems
Case Study: Shell & tube exchanger optimization in oil refinery

Module 3: Economizers and Recuperators

Working principles of economizers
Flue gas heat recovery systems
Furnace heat recovery techniques
Recuperator design and applications
Efficiency improvement calculations
Case Study: Boiler economizer installation in a power plant

Module 4: Organic Rankine Cycle (ORC) Systems

ORC working principle and components
Low-grade heat utilization
Working fluids selection
Power generation from waste heat
Performance optimization
Case Study: ORC system in geothermal and industrial waste heat plant

Module 5: Industrial Heat Integration & Pinch Analysis

Introduction to pinch technology
Heat cascade analysis
Minimum energy targeting
Process integration strategies
Software tools for heat integration
Case Study: Heat integration in petrochemical complex

Module 6: Energy Efficiency & Decarbonization

Industrial energy benchmarking
Carbon emission reduction methods
Energy recovery ROI analysis
Net-zero industrial pathways
Sustainability reporting
Case Study: Steel plant carbon reduction using WHR

Module 7: WHR System Design & Simulation

Thermodynamic modeling
Simulation tools
System sizing and selection
Economic feasibility analysis
Risk assessment in WHR projects
Case Study: Simulation of WHR system in cement kiln

Module 8: Smart Energy Systems & Industry 4.0 Integration

IoT-based energy monitoring
Predictive maintenance for WHR systems
AI-driven energy optimization
Digital twin technology in energy systems
Smart grid integration
Case Study: Smart WHR monitoring system in manufacturing plant

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

Heat recovery Energy efficiency Thermal integration Process 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