COURSE OVERVIEW:

The Vacuum Distillation Unit (VDU) is essential for maximizing the recovery of high-value gas oils from atmospheric residue while preventing the thermal degradation of heavy hydrocarbons. This course provides a technical exploration of the VDU process, focusing on the physics of deep vacuum fractionation and the mechanical design of the vacuum tower. Participants will examine the relationship between absolute pressure and boiling points to understand how the VDU enables the separation of heavy distillates at temperatures below their cracking point.

The scope of this training involves the detailed analysis of the vacuum-creating systems, including multi-stage steam ejectors and liquid ring vacuum pumps. Attendees will learn about the design of vacuum tower internals, such as high-capacity structured packing and specialized liquid distributors, which are critical for maintaining low pressure drop. The course emphasizes the importance of managing the "wash oil" section to ensure gas oil quality and protect downstream units from metals and carbon residue.

Coverage includes advanced troubleshooting for common VDU issues, such as air leaks, ejector fouling, and tower flooding. Participants will explore the optimization of the vacuum furnace, focusing on the prevention of tube coking during high-severity operations. By integrating process simulation with field-proven diagnostic tools, this course equips engineers and senior operators with the expertise to maximize VGO yields, improve energy efficiency, and maintain the mechanical integrity of the vacuum system.

COURSE OBJECTIVES:

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

1.  Explain the thermodynamic advantages of vacuum vs. atmospheric distillation.

2.  Optimize the performance of steam ejector systems and surface condensers.

3.  Manage vacuum tower pressure profiles for maximum VGO recovery.

4.  Evaluate the impact of structured packing on separation and pressure drop.

5.  Control the vacuum furnace to maximize heat input while avoiding coking.

6.  Manage wash oil rates to control VGO color and metal content.

7.  Identify and locate air ingress points using vacuum decay and ultrasonic tests.

8.  Troubleshoot poor vacuum caused by motive steam or cooling water issues.

9.  Optimize the production of Heavy Vacuum Gas Oil (HVGO) for FCC/Hydrocracker feed.

10.  Manage the quality and viscosity of Vacuum Residue for coker or bitumen service.

11.  Execute safe procedures for unit start-up, shutdown and emergency cooling.

12.  Analyze the impact of non-condensable gases on vacuum system capacity.

13.  Utilize heat and mass balances to identify unit bottlenecks.

TARGET AUDIENCE:

VDU Process Engineers, Operations Supervisors, Senior Board Operators, and Technical Professionals responsible for heavy oil processing.

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.