COURSE OVERVIEW:

Caustic treating is a specialized chemical wash process used extensively in refineries and petrochemical plants to remove acidic contaminants such as hydrogen sulfide, mercaptans, and organic acids from hydrocarbon streams. This course provides a technical deep dive into the chemistry of neutralization and extraction, focusing on the design of contactors and regenerators. Participants will explore the balance between caustic concentration, temperature, and residence time required to meet stringent product specifications for liquefied petroleum gas, gasoline, and kerosene.

The scope of this training involves a detailed analysis of the various caustic treating configurations, including regenerative systems for mercaptan extraction and non-regenerative systems for simple neutralization. Attendees will examine the mechanical internals of extraction columns, such as tray designs and packing, that facilitate efficient mass transfer between the aqueous caustic phase and the organic hydrocarbon phase. The course emphasizes the importance of preventing caustic carryover and managing the interface to protect downstream equipment from corrosion and catalyst poisoning.

Coverage includes the operational management of spent caustic and the environmental challenges associated with its disposal or treatment. Participants will learn about the chemistry of pre-washing and post-washing steps, as well as the specialized requirements for cobalt-phthalocyanine catalysts in mercaptan oxidation (MEROX) units. By integrating design principles with troubleshooting techniques, this course equips engineers and operators with the skills to maintain high treat efficiency while minimizing caustic consumption and optimizing the lifecycle of the chemical inventory.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the fundamental chemistry of acid gas removal using sodium hydroxide solutions.
2. Differentiate between mercaptan extraction and sweetening processes.
3. Design and size caustic-hydrocarbon contactors based on mass transfer requirements.
4. Optimize the concentration of circulating caustic to maximize pollutant removal.
5. Identify the causes and solutions for stable emulsions and interface issues.
6. Manage the regeneration of caustic using air and catalyst in oxidative systems.
7. Implement effective pre-wash strategies to remove hydrogen sulfide and salts.
8. Evaluate the performance of salt towers and coalescers in preventing carryover.
9. Monitor and control the consumption of catalyst in MEROX-style units.
10. Diagnose fouling and plugging in caustic heaters and exchangers.
11. Execute safe procedures for caustic handling, dilution, and storage.
12. Analyze the impact of feed contaminants on caustic life and byproduct formation.
13. Formulate an environmental management plan for the treatment of spent caustic.

TARGET AUDIENCE:

Process Engineers, Operations Supervisors, Laboratory Chemists, and Technical Personnel involved in refinery treating and finishing units.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.