Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Petrochemical Processing

• Understand the role of petrochemical plants in the industry.
• Learn about key feedstocks such as natural gas, crude oil fractions, and chemical intermediates.
• Identify major petrochemical products including ethylene, propylene, benzene, toluene, and xylene (BTX).

2. Process Flow and Key Petrochemical Units

• Gain knowledge of primary processing units, including:
• Steam cracking and catalytic reforming
• Olefin and aromatics production
• Polymerization and synthesis gas processing
• Understand key plant functions such as reaction control, heat integration, and catalyst management.

3. Equipment Used in Petrochemical Plants

• Operate and maintain critical equipment, including:
• Reactors and reformers
• Distillation columns and separators
• Heat exchangers and cooling towers
• Compressors, pumps, and piping systems
• Perform routine inspections and troubleshoot common equipment failures.

4. Safety and Hazard Management in Petrochemical Plants

• Recognize hazards related to flammable gases, toxic chemicals, and high-pressure operations.
• Follow safety protocols for chemical handling, storage, and transportation.
• Implement emergency response plans for fires, leaks, and explosions.
• Use personal protective equipment (PPE) and gas detection systems.

5. Process Control and Optimization

• Monitor key process parameters such as temperature, pressure, and flow rates.
• Utilize Distributed Control Systems (DCS) and Supervisory Control and Data Acquisition (SCADA) systems for plant monitoring.
• Apply best practices in process optimization to enhance efficiency and yield.

6. Environmental Compliance and Waste Management

• Understand regulatory requirements for emissions, effluents, and hazardous waste disposal.
• Implement pollution control measures such as scrubbers, flare systems, and wastewater treatment.
• Ensure compliance with national and international environmental standards.

7. Maintenance and Reliability of Petrochemical Units

• Develop preventive and predictive maintenance strategies for petrochemical equipment.
• Identify common causes of equipment failure and implement troubleshooting techniques.
• Enhance reliability through condition monitoring and risk-based inspections.

8. Case Studies and Practical Applications

• Analyze real-world examples of petrochemical plant operations and best practices.
• Participate in hands-on training for process troubleshooting and problem-solving.
• Develop strategies to improve safety, efficiency, and compliance in plant operations.

Target Audience

• Petrochemical plant operators and field technicians
• Process and maintenance engineers
• Shift supervisors and plant managers
• Safety and environmental compliance officers