COURSE OVERVIEW:

Cold box operations are the core of cryogenic gas processing units, enabling the separation of air, natural gas, or synthesis gas into their high-purity components at extremely low temperatures. This course provides an in-depth exploration of the design and operation of vacuum-insulated cold boxes, focusing on the integration of plate-fin heat exchangers and cryogenic distillation columns. Participants will examine the thermodynamics of refrigeration cycles, including Joule-Thomson expansion and turbo-expander processes, to understand how cryogenic temperatures are achieved and maintained.

The scope of this training involves the detailed analysis of process variables such as pressure, temperature, and composition that govern the efficiency of cryogenic separation. Attendees will explore the mechanical challenges of operating at temperatures below -150 degrees Celsius, including the management of thermal contraction, perlite insulation integrity, and the prevention of freeze-out from contaminants like water and carbon dioxide. The course emphasizes the importance of precise control during start-up and warm-up sequences to avoid mechanical stress and equipment damage.

Coverage includes specialized troubleshooting techniques for identifying heat exchanger leaks, insulation degradation, and column flooding within the enclosed cold box environment. Participants will learn how to manage the transition between different operating modes and optimize the production of liquefied products such as LNG, liquid oxygen, and nitrogen. By integrating cryogenic safety principles with practical operational logic, this course equips engineers and operators with the expertise to manage complex cold box systems with high reliability and efficiency.

COURSE OBJECTIVES:

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

1.  Explain the fundamental principles of cryogenic separation and refrigeration.

2.  Identify the internal components and structural design of a process cold box.

3.  Optimize the performance of plate-fin heat exchangers (PFHE) in cryogenic service.

4.  Manage refrigeration cycles using turbo-expanders and JT valves.

5.  Execute safe start-up and cooldown procedures for cryogenic equipment.

6.  Identify and mitigate the risks of "freeze-out" from water and CO2 contaminants.

7.  Monitor the integrity of vacuum and perlite insulation systems.

8.  Diagnose internal leaks and bypasses using temperature profile analysis.

9.  Execute controlled warm-up (derime) procedures to remove accumulated solids.

10.  Manage the production and storage of liquefied gas products safely.

11.  Implement specialized safety protocols for oxygen-enriched and inert atmospheres.

12.  Troubleshoot column instabilities and flooding in cryogenic distillation.

13.  Formulate a maintenance strategy for cryogenic valves and instrumentation.

TARGET AUDIENCE:

Cryogenic Plant Operators, Process Engineers, Gas Plant Managers, and Technical Personnel involved in LNG, ASU, or Hydrogen processing 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.