About
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
- A - Process Engineering Discipline Deliverables
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
Training Methodology
Pathways Training and consulting adopts the newest techniques of human resources Training and consulting and, with the following:
- Theoretical lectures are delivered via PowerPoint and visual displays (videos and short films)
- Making scientific evaluation to the trainee (before and after)
- Brainstorming and role-playing
- Using case studies related to the scientific material being delivered and the trainees' work.
- The participants get the scientific and practical material printed and on CDs and Flash memories.
- Preparing records and reports of the participants' attendance and results, with a general evaluation of the training program.
- A group of the best trainers and experts in all fields and specialties professionally prepares the scientific material.
- After finishing the course, the participants get certificates of attendance signed, certified, and issued by pathways Training and consulting.
- Our training programs start at 9:00 o'clock in the morning and end at 2:00 in the afternoon, with snack buffet during the lectures.
- Providing a lunch buffet during the training program period, with organizing a lunch party on the training program final day for taking some photos and certificate awarding.
