Learning Objectives

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

1. Fundamentals of Reactors, Extruders, and Extractors

• Understand the principles and applications of reactors, extruders, and extractors in industrial processes.
• Identify different types of reactors, extruders, and extraction systems used in chemical and petrochemical industries.
• Learn about feedstock selection and material handling in these processes.

2. Reactor Operations and Process Control

• Differentiate between types of reactors, including:
• Batch reactors
• Continuous stirred tank reactors (CSTR)
• Plug flow reactors (PFR)
• Fixed-bed and fluidized-bed reactors
• Understand chemical reaction kinetics and catalysts in reactor performance.
• Monitor key parameters such as temperature, pressure, and reaction time.
• Operate Distributed Control Systems (DCS) and sensors for process monitoring.
• Perform troubleshooting for common reactor issues such as overheating, fouling, and catalyst deactivation.

3. Extruder Operations and Processing Techniques

• Learn about the function and applications of extruders in polymer processing and food production.
• Operate different types of extruders, including:
• Single-screw extruders
• Twin-screw extruders
• Reactive and compounding extruders
• Understand temperature control, screw speed, and pressure regulation for optimal extrusion.
• Identify and troubleshoot common extrusion defects such as die swell, melt fracture, and inconsistent flow.
• Implement maintenance practices for extruder barrels, screws, and die heads.

4. Extraction Processes and Equipment Operations

• Understand different extraction methods used in chemical, oil, and pharmaceutical industries.
• Operate key extraction systems, including:
• Liquid-liquid extraction (LLE)
• Solid-liquid extraction (SLE)
• Supercritical fluid extraction (SFE)
• Control solvent flow, temperature, and agitation to maximize extraction efficiency.
• Monitor key process parameters to optimize yield and purity.
• Troubleshoot common extraction issues such as emulsion formation, solvent losses, and inefficient mass transfer.

5. Safety and Hazard Management in Reactor, Extruder, and Extractor Operations

• Recognize potential hazards such as high temperatures, high pressures, and toxic materials.
• Follow industry safety protocols for handling chemicals and high-pressure equipment.
• Implement emergency response procedures for spills, leaks, and fire hazards.
• Utilize personal protective equipment (PPE) and safety interlocks in process equipment.

6. Maintenance, Reliability, and Process Optimization

• Develop preventive and predictive maintenance strategies for reactors, extruders, and extractors.
• Implement best practices for equipment cleaning and downtime reduction.
• Optimize operating conditions for improved efficiency and reduced energy consumption.
• Utilize automation and process control systems for improved reliability and troubleshooting.

7. Environmental Compliance and Waste Management

• Understand environmental regulations and waste management practices in chemical processing.
• Implement emissions control, solvent recovery, and effluent treatment systems.
• Ensure compliance with workplace safety and environmental regulations.

8. Case Studies and Practical Applications

• Analyze real-world examples of reactor, extruder, and extractor operations.
• Participate in troubleshooting exercises and process optimization scenarios.
• Develop a proactive approach to improving plant efficiency and safety.

Target Audience

• Chemical and petrochemical plant operators
• Polymer processing and plastics industry operators
• Process and maintenance engineers
• Safety and environmental compliance officers
• Production supervisors and shift leaders