Learning Objectives

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

1. Fundamentals of Process Technology

• Understand basic principles of mass and energy transfer in process systems.
• Learn about unit operations (separation, heat exchange, reaction engineering, distillation, etc.).
• Identify flow dynamics and pressure drop considerations in pipelines and equipment.

2. Process Design and System Integration

• Develop Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs).
• Optimize process design using heat integration and pinch analysis.
• Understand process control loops and instrumentation for efficient operation.

3. Industrial Equipment and Operational Principles

• Learn about key process equipment and their applications:
• Heat exchangers (shell & tube, plate, air-cooled).
• Pumps and compressors (centrifugal, reciprocating, screw, diaphragm).
• Distillation and separation columns.
• Reactors (batch, CSTR, PFR).
• Optimize equipment performance through process simulation tools (Aspen HYSYS, PRO/II, ChemCAD).

4. Process Control and Automation

• Implement Distributed Control Systems (DCS) and Programmable Logic Controllers (PLC).
• Learn Advanced Process Control (APC) techniques to optimize plant efficiency.
• Integrate Supervisory Control and Data Acquisition (SCADA) systems for real-time monitoring.

5. Safety and Risk Management in Process Technology

• Conduct HAZOP (Hazard and Operability Study) and LOPA (Layer of Protection Analysis).
• Implement Process Safety Management (PSM) and emergency shutdown systems.
• Ensure compliance with OSHA, API, ASME, NFPA, and other safety standards.

6. Process Optimization and Energy Efficiency

• Identify key performance indicators (KPIs) for process efficiency.
• Apply Lean Six Sigma methodologies to reduce waste and increase throughput.
• Optimize steam, compressed air, and utility systems to improve energy efficiency.

7. Troubleshooting and Problem-Solving in Process Operations

• Identify common operational problems (fouling, corrosion, pressure loss, flow instabilities).
• Use Root Cause Analysis (RCA) and Failure Modes and Effects Analysis (FMEA) for problem-solving.
• Implement predictive maintenance and reliability engineering strategies.

8. Case Studies and Practical Applications

• Review real-world process optimization case studies.
• Participate in hands-on troubleshooting and simulation exercises.
• Develop a process improvement plan tailored to a specific industry challenge.

Target Audience

• Process and chemical engineers
• Operations and plant managers
• Equipment and maintenance engineers
• Industrial automation and control specialists
• HSE and risk management professionals