Course details

Overview ?

Course Overview

This course is aimed at non-chemical engineers who need an overview of the function, principles, requirements, and operation of typical chemical process equipment and who need to communicate effectively with chemical / process engineers by gaining a basic understanding of the operational factors and design equations that are used by chemical engineers and how chemical engineering relates to their disciplines.

What you will learn

Role, need, and goal of chemical engineering in today’s world
Three elements of process plants including equipment, utilities, and instrumentation and control
Process engineers knowledge Concepts, Skills, Deliverables, Codes & Standards
Process engineering concepts related to two main elements of chemical engineering; material and material changes; including: different material phases (solid, liquid and gas), fluid properties, gas law, material properties, physical operations vs. chemical processes, etc.
Different process discipline deliverables including: BFD, PFD, P&ID, H&MB Table, process design criteria and process design basis, process description, process control narrative, and cause and effect table and gaining ability to read and interpret them
Concepts and applications of different process elements including: pipes, valves, automatic valves (switching valves and control valves), containers (vessels and tanks), fluid movers (pumps, compressors, blowers, fans), heat exchangers, and furnaces
Common principles of “change” either physical or chemical
Different unit operations including Gravity Separation, Filtration, Absorption & Adsorption, Evaporation, Distillation, Crystallization, Centrifugation, Drying, Extraction, Leaching, Membrane separation, Cyclones, Humidification, and Dehumidification
Safety requirements of process plant and technical and legal issues related to Pressure Relief Devices (PRD) including Pressure Safety Valves (PSV) and rupture discs in the process plants
Impact of process plants on three elements of environment, air, water, and soil
Risk management and risk management tools in process industries including HAZOP
Profitability of process plants including capital, operating cost, and unit product cost estimation
Material of construction in process plants and different mechanisms of material loss including corrosion and erosion.

Course Outline

Day 1

Chemical Engineering

What is this course about?
What is chemical engineering about?
What do chemical engineers study in university and why?
Which sectors do chemical engineers work in?
Different types of Process industries
What do we need to study to learn chemical engineering quickly?
Process Plants: A tangible way to start learning chemical engineering
Process Plant Elements: Equipment, Utility Generation & Network, and Instrumentation & Control (I&C)

Day 2

Process Industries Elements: Equipment and Pipes (Applications)

Fluid Conductors: Pipes, Tubes, Ducts
Pipe Appurtenances: Fitting and Valves
Fluid Movers: Pumps and Compressors
Containers: Tanks, Vessels
Heat Transfer Equipment: Heat Exchangers, Furnaces
Unit Operations and Unit Processes

Process Industries Elements: Utility

Different Utilities in Plants
Utilities Generation
Utility Distribution and Collection Networks
Permanent vs. Temporary Utility Users

Day 3

Process Industries Elements: Instrumentation and Control

The Value of Control; and Parameters of Interest
Three Layers of Integrated Control & Safety System (ICSS): BPCS, Alarm, and SIS
Control Loop: Duty and Components
Three Main Elements of Control Loops: Control Architecture, Control Strategy, and Tuning
Primary Elements: Sensors and Meters
Final Elements: Control Valves
Safety Instrumented Function: Duty and Components
Final Elements: Switching Valves
Alarm System: Duty and Components

Day 4

Chemical Engineers' Assets - Part 1

Chemical Engineers' Assets: Concepts, Skills, Deliverables, Codes & Standards
- A - Process Engineering Discipline Deliverables
  - BFD (Block Flow Diagram)
  - PFD (Process Flow Diagram)
  - Plot Plan; and Site Selection
  - P&ID (Piping & Instrumentation Diagram)
  - H&MB Table (Heat & Material Balance)
  - Equipment Datasheets
  - Process Description and Process Control Narrative
  - Datasheets
  - Utility Consumption Table
  - Chemical Consumption Table
  - Shut-Down Key Table
  - Alarm Set Point Table
- B - Process Engineers' Skills
  - Calculation
  - Study Report
  - SOP (Standard Operating Procedure)
  - Scope Definition Document
- C - Process Engineering Standards and Codes
  - Standards vs. Codes
  - Common Standards in Chemical Engineering
  - Common Codes in Chemical Engineering
- D - Process Engineering Concepts

Day 5

Substances

Material Phases: Solids, Liquids, and Gasses
- Phase Behaviour
- Gas Laws
- Material Properties
- Properties of Flowable Solids
- Change: Physical or Chemical
- Physical Change: Macro-Change, Micro-Change (Phase and Component Changes)
- Chemical Change: Reactions
Principles of Material Change
- Mass Transfer and Energy Transfer (Potential and Kinetic)
- Transfer Phenomena: Heat Transfer, Mass Transfer; and Momentum Transfer
- Conservation of Energy, Mass; and Momentum
- Energy Balance, Mass Balance

Day 6

Process Industries Elements: Equipment and Pipes (Concepts)

Fluid Conductors: Pipes, Tubes, Ducts
Fitting and Valves
Fluid Movers: Pump and Compressors
Containers: Tanks, Vessels
Mixing and Agitation
Heat Transfer Equipment: Heat Exchangers, Furnaces
Unit Operations and Unit Processes
Flowable Solid Transfer

Day 7

Common Principles of Change

Type of change: Physical or chemical
Possibility (thermodynamic) and speed (Kinetics)
End point vs. equilibrium point
Phase equilibrium and Reaction equilibrium
Containers for “change"

Unit Operations: Solid Handling

Size reduction (comminution)
Crushers
Grinders

Day 8

Unit Operations: Separation Methods - Part 1

Screening
Gravity Separation
Filtration
Absorption & Adsorbtion
Evaporation
Distillation
Crystallization
Centrifugation
Drying
Extraction
Leaching
Membrane
Cyclones
Cooling Towers, Humidification, and Dehumidification

Day 9

Process Units: Reactions

What is a reactor?
Different types of reactors: Plug and Mixed
Single Phase vs. Multiphase
Endothermic vs. Exothermic

Day 10

Process Plant Design

Batch vs. Continuous
Steady State vs. Unsteady State
Hierarchy of Document Generation
Simulation
Sizing vs. Specification
Series and Parallel Process Items

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Day 5

Training Methodology

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