COURSE OVERVIEW

This course provides participants with a comprehensive understanding of the operation, control, and troubleshooting of reactors, extruders, and extractors commonly used in petrochemical and polymer production plants. It focuses on the functional principles, process flow, and safe operation of these key units, ensuring smooth and efficient plant performance.

Participants will gain insight into reactor systems and their supporting catalyst injection and co-catalyst systems, followed by the extrusion and extraction processes that are critical for polymer finishing and product quality. The course emphasizes the integration of these systems in continuous production environments and the role of operators in monitoring parameters, preventing upsets, and optimizing process performance.

Through real-world examples and operational scenarios, the training helps participants develop the technical knowledge and problem-solving skills required to ensure safe, reliable, and high-quality petrochemical operations.

COURSE OBJECTIVES:

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

1. Understand the basic operation and function of reactor, extruder, and extractor systems in petrochemical plants.
2. Explain the role of catalysts, co-catalysts, and support systems in polymerization and other chemical reactions.
3. Recognize the main control parameters affecting reactor performance such as temperature, pressure, and flow rates.
4. Learn about extruder systems, including operation principles, temperature control, and product handling.
5. Understand the function of extraction systems in polymer finishing and purification processes.
6. Identify common operational problems and develop troubleshooting techniques for each unit.
7. Learn how to coordinate field and control room operations during startups, shutdowns, and upsets.
8. Gain awareness of safety practices, interlocks, and emergency procedures related to high-temperature and high-pressure systems.
9. Enhance understanding of equipment maintenance, cleaning, and inspection requirements.
10. Apply best practices for steady-state operation and process optimization to maintain high efficiency and product quality.

TARGET AUDIENCE

-Control Room Operators

-Field Operators

-Process Technicians

-Operations Supervisors

-Junior Process and Chemical Engineers

-HSE and Maintenance Technicians

TRAINING COURSE METHODOLOGY

A highly interactive combination of lectures and discussion sessions, as well as case studies, will be managed to maximize the amount and quality of information, knowledge, and experience transfer. The course will be intensive but 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 learning. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and after 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.