:: DEFINE | Management Consultancy & Training Provider In UAE, Abu Dhabi,Dubai,Saudi Arabia ::

PILOT PLANT OPERATIONS FOR REFINING PROCESSES & PROCESS TROUBLESHOOTING

Location

Dubai, UAE

Date

From Date: 05-May-2025
To Date: 09-May-2025

Duration

5 days

Language

ENGLISH

Discipline

PROCESS ENGINEERING, WATER DESALINATION & CHEMICAL ENGINEERING

Introduction

The Refinery is the engine of the oil industry where Crude is converted into fuels and lubes available for consumption by its customers. This needs to be done safely and efficiently. Pilot plant operation helps clients improve petroleum refinery production, quality and efficiencies. Capabilities range from crude oil introduction by desalting and distillation through reside upgrading applications. The refining pilot plants evaluate process and catalyst upgrades, troubleshoot refining operations, optimize production facilities, and prove the design basis for commercial applications.

This course gives an overview of the elements of the refining process and provides an insight into the criteria used to size and rate the individual components. Starting with the feedstock, the participant is gradually introduced to the various processes used to convert the crude into finished products. Troubleshooting of the processes and components is then introduced to allow the participant to analyze a system and restore it to a safe and operable state.

Objective

By the end of the training course, participants will be able to:

A comprehensive overview of the Refining process from crude sourcing and analysis to product specifications and applications.
Knowledge of fractionation of heavy and light hydrocarbon systems.
Knowledge of hydro processing catalytic systems.
Knowledge of conversion and octane processes.
An understanding of the processes, equipment and procedures of the design, operation and control of Refineries.
In addition, the unit operations of mass, heat and momentum transfer as applicable to refining are also developed including selection and sizing of heat exchangers, pumps, compressors, piping and control valve.
Finally, a systematic approach to troubleshooting of refining processes is developed including a section on root cause analysis.

Audience

This course is a comprehensive core skills course for professionals dealing with all aspects of the Refining Industry. The course will be highly valuable to all engineers involved in the operation, design and troubleshooting of all refining facilities. Additionally, the course will be useful to any technical personnel wishing to gain a perspective of how Refining fits into the operation of an integrated oil company. Those who are experienced in other fields and seek a review of the fundamentals of refining will also find this course most beneficial.

Content

COURSE OUTLINE: -

Crude Oil Origin and Characterization
Product Specifications and Applications
Fractionation of Heavy and Light Hydrocarbons
Hydro processing of Hydrocarbon Streams
Octane and Conversion Process
Process Control
Troubleshooting Refining Processes
Q&A Sessions

Day-1

Course Introduction & Pre-assessment
Crude Oil Introduction

Origin, production and transport of crude oil

Crude Oil and Product Types

Classification of crudes
Product specifications of crude oil cuts
End Users specifications for gasoline, diesel, jet fuel
Online blending of products

DAY-2

General Refinery Processes

Refinery overview and organization
Hydro skimming refinery, complex refinery, petrochemical refinery
Petroleum chemistry
Distillation basics
Trays, multidoctor trays, structured packing

Conversion Processes

Fixed bed hydrocracking
Emulating bed hydrocracking
Vis breaking
Thermal cracking
Delayed coking
Fluid coking
Fluid catalytic cracking

Q&A Session, exercises

Day-3

Octane Processes

Alkylation (HF alkylation, sulfuric acid alkylation)
Reforming (CCR reformer, catalyst regeneration, benzene precursors)
Isomerization (including de-isopentane and de-Schexnaider)
MTBE/ETBE

Hydrotreating Processes

Steam reformer (hydrogen plant)
Chemistry of hydrotreating
Catalysts
Product yields and properties
Operating conditions and process variables
Desulfurization, aromatic saturation
Mild hydrocracking
Upgrading of aromatic gasoil and kerosene

Sulfur Recovery

Amine wash
Amine regeneration
Claus process

Q&A Session, exercises

Day-4

Unit Operations

Heat exchangers
Pumps
Compressors
Control valves
Drums

Troubleshooting

Root cause analysis
Troubleshooting aids
Distillation
Fouling / coking
Pump failures
Incident causation
Control systems

Case studies
Q&A Session

Day-5

Process Control

Instrumentation
Regulatory control
Constraint control

Optimization

Refinery Material Balance
Hydrogen Consumption
Reaction Kinetics

Process Emergency and Safeguarding in Pilot Plant

Course Closing and Final Assessment

NOTE:

Pre & Post Tests will be conducted

Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.

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Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences. Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

30% Lectures
30% Workshops and work presentation
20% Group Work& Practical Exercises
20% Videos& General Discussions

Course Details