Phase 1 Thermal Engineering Fundamentals
Module 1 - Heat Transfer Engineering
Conduction
Convection
Radiation
Stefan Boltzmann Law
Heat balance
Furnace efficiency
Module 2 - Combustion Engineering
Air fuel ratio Excess air Fuel gases
LPG / PNG / FO / HSD / Hydrogen
Burner fundamentals
Flame characteristics
NOx & CO generation
Phase 2 Steel Mill Furnaces
Module 3 - Continuous Steel Mill Furnaces
Pusher Furnaces
Slab movement philosophy
Skid marks
Temperature uniformity
Reheating concepts
Walking Hearth Furnaces
Hearth movement
Heat distribution
Mechanical synchronization
Walking Beam Furnaces
Beam mechanism
Water cooled beams
Beam failure troubleshooting
Rotary Hearth Furnaces
Circular heating philosophy
Drive system
Sealing issues
Phase 3 Heat Treatment Furnaces
Module 4 - Batch & Continuous Heat Treatment Furnaces
Roller Hearth Furnace
Conveyor Furnace
Bogie Hearth Furnace
Top Hat Furnace
Chamber Furnace
Integral ǫuench Furnace
Hardening
Annealing
Tempering
Normalizing
Stress relieving
Metallurgical properties
Phase 4 CONTINUOUS GALVANIZING LINE (CGL)
Module 5 - Galvanizing Process Engineering
Heating Sections
Horizontal NOF
Vertical NOF
ART heating systems
Cooling Systems
Jet cooling
Cooling after galvanizing
Quenching
Zinc Pot Area
Pot furnaces
Zinc bath temperature
Dross formation
Strip Handling
Hot bridle
Jet wiping machines
Phase 5 COLOR COATING LINES (CCL)
Module 6 - Paint & Coating Oven Systems
Catenary Convection Ovens
Thermal Oxidizers
Heat Recovery Systems Topics:
VOC treatment
Solvent burning
Exhaust systems
Oven airflow balancing
Phase 6 CONTINUOUS ANNEALING LINES (CAL)
Module 7 - Annealing Line Technology
Vertical Annealers
Horizontal Annealers
Stainless Steel Annealers
Copper & Brass Annealers
Topics:
Strip metallurgy
Controlled atmosphere
Hydrogen furnace safety
Cooling curves
Phase 7 Aluminium Furnaces
Module 8 - Aluminium Thermal Systems
Melting Furnaces
Holding Furnaces
Homogenizing Furnaces
Aging Furnaces
Topics: Molten aluminium handling
Burner optimization
Metal loss reduction Energy efficiency
Phase 8 Ceramic & Kiln Engineering
Module 9 - Kiln Technology
Tunnel Kilns
Shuttle Kilns
Bell Kilns
Tempering Kilns Dryers
Topics:
Firing curves
Ceramic heating zones
Kiln atmosphere
Refractory failures
Phase 9 Lime & Dolomite Kilns
Module 10 - Calcination Technology
Lime production
Dolomite processing
Rotary kiln operation
Fuel optimization
Phase 10 Furnace Design Engineering
Module 11 - Furnace Design Basics
Design Topic
Heat load calculation
Burner sizing
Refractory selection
Insulation thickness
Draft calculation
Air requirement
Mechanical Design Awareness
Expansion joints
Structural supports
Skid systems
Cooling systems
Phase 11 Combustion & automation
Module 12 - Automation Systems
PLC Basics
Burner Management System (BMS)
SCADA
Interlocks Safety systems Topics:
Flame scanners
Purging sequence
Emergency shutdown
Oxygen trim control
Phase 12 Refractory Engineering
Module 13 - Refractory Technology
Castables
Ceramic fiber
Fire bricks
Anchor systems
Refractory dryout
Phase 13 Troubleshooting Masterclass
Module 14 - Industrial Troubleshooting
Common Failures
Temperature non uniformity
Flame instability
High fuel consumption
Refractory collapse
Strip defects
Oxidation
Burner trips
Coil overheating
Furnace pressure instability
RCA Techniques
Root cause analysis
CAPA
Failure investigation
Phase 14 Vendor Document Engineering
Module 15 - EPC & Vendor Documentation
GA drawing
Instrument list
Datasheet
Burner drawings
Refractory layout
Heatbalancesheet
Phase 15 Site & Commissioning
Module 16 - Erection & Commissioning
Alignment
Dryout procedure
Burner tuning
Refractory curing
SAT/FAT
Performance guarantee test
