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

PROCESS TECHNOLOGY

Location

Dubai, UAE

Date

From Date: 22-Sep-2025
To Date: 26-Sep-2025

Duration

5 days

Language

ENGLISH

Discipline

PROCESS ENGINEERING

Introduction

Refiners are facing a dynamic business environment. Crude prices are volatile. Heavy, high-sulfur and acidic opportunity crudes are increasingly available. Demand for lighter products is increasing; product legislation and emissions standards are tightening; and health, safety and environment mandates also have to be met. This necessitates that refiners are now required to reduce the products sulfur content before it can be sold and satisfy market demand of lighter products. This is most commonly done by hydro-processing. Hydro-treating and hydrocracking processes share many common features, so they often are discussed together as “hydro-processing.” Hydro-treating removes contaminants from distilled crude oil fractions and intermediate process streams. Hydrocracking converts heavy oil fractions into lighter, more valuable products.

For refiners to sustain their profit margins, economical access to state-of-the-art technology is a must. Hence, this course is designed to provide in depth practical review of all hydro-treating and hydrocracking processes key variables that affect product yields, properties, catalyst issues, reaction mechanisms, process design, operation, control, troubleshooting and optimization. Several significant product quality specifications (for instance, ultra-low sulfur diesel and gasoline), nitrogen and aromatic content, Cetane number, API gravity, smoke point, cold flow properties such as pour point, cloud point and cold filter plug point and many other topics will be deeply discussed in this course.

A framework is presented for troubleshooting operating problems and, throughout this discussion, participants are encouraged to describe their specific challenges.

Objective

By the end of the course, participants will be able to understand

Gain in-depth knowledge of the exact role of hydro-treating and hydrocracking unit regarding to feeds and product's characteristics, analyze the importance and impact of operating parameters on process output, identify common potential incidents in the reaction section: origin, consequences, solutions and preventive measures.
Evaluate different flow schemes for Hydro-treating and Hydrocracking processes.
Understand process design and operation variables for better H₂-conversion performances.
Grasp the experiences of chemistry/kinetics, function of catalysts, clean production, environmental issues of very typical upgraded fuel productions.
Develop deep understanding of mass/H₂/energy balance in refining processes.
Identify Hydro-processing unit-specific problems and describe typical solutions.

Audience

This course is intended for anyone who takes part in the Hydro-processing facilities in oil refining and petrochemical industries or who helps decide Hydro-processing investments.

The course is suitable to a wide range of professionals but will greatly benefit to:

Refinery operation managers
Process Engineers and technologists
Operation engineers
Shift team leaders
Maintenance Engineers
Plant Engineers
All professionals involved in refinery process unit operations
Anyone who wishes to update himself on the methods used in this important field

Content

Module-1

Refining Operations and Introduction to Hydroprocessing

Refinery Feed stocks and Products
Crude Assay and Quality
Refinery Configurations
Physical Separation Processes
Chemical Catalytic Conversion Processes
Thermal Chemical Conversion Processes
Role of Hydroprocessing in refineries: Development of New Technologies
New Trends for Clean Fuel Productions
Recent developments in Hydro-treatment and Hydro-conversion of heavy residues
Environmental Regulation

Module-2

Hydrotreating Process Description

Objectives and Roles of Hydrotreating
Chemistry of Hydrotreating
Hydrotreating Catalysts
Thermodynamics of Hydrotreating
Reaction Kinetics
Hydrotreating Applications
Applications to Naphtha, Middle Distillates, Gas Oil, ARD,...
Different Process Flow Schemes
Operating Conditions

Module-3

Hydro-treating Unit Operation and Design

Process Variables
Reactor Design
Recycle Gas Purity
Wash Water
Makeup Gas Compression
Clean Diesel Hydro-treating Process Technology – Critical Issues
Recent developments in Hydro-treatment and Hydro-conversion of Heavy Residues
Deep Desulfurization
Startup, shutdown and normal operating procedures

Module-4

Hydrocracking Process Description

Role of Hydrocracking in the Refinery
Feeds and Products
Hydrocracking Chemistry and Catalysts
Thermodynamics and Kinetics of Hydrocracking
Different Hydrocracking Processes
Process Configurations
Process Flow Schemes and Equipment
Operating Conditions and Process Severity
Reactor Technologies for Hydrocracking

Module-5

Hydrocracking Unit Operation and Design

Process Variables
Single-stage Hydrocracking Reactor Section
Two-stage Hydrocracking Reactor Section
Use of a Hot Separator in Hydrocracking Unit Design
Use of Flash Drums
Fractionation Section Design
Hydrogen Recovery
LPG Recovery

HPNA Rejection
Startup, Shutdown and Normal Operating Procedures (including catalyst activation)

Module-6

Hydro-processing Operational Guidelines and Troubleshooting

Catalyst Activation Problems
Feedstock Variations and Contaminants
Operation Upsets
Treating/Cracking Catalyst Deactivation Imbalance
Flow Maldistribution
Temperature Excursion
Reactor Pressure Drop
Troubleshooting Case Analysis:

Case Analysis-1: Catalyst Deactivation

Case Analysis-2: Catalyst Channeling

Case Analysis-3: Reactor Bed Temperature Maldistribution

Case Analysis-4: Off-Spec Product Quality

Case Analysis-5: Reactor Temperature Runaway During Catalyst Regeneration

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and 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