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.

• 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.

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