Overview

Early-Career Engineer Fractionation Operations SIM-FOE

About the Course

A student-driven learning paradigm based on the INSTO Methodology is combined with high fidelity, generic process simulators in this interactive, two-day course. Early-career engineers have the chance to investigate the same system dynamics and process disruptions that plant operators deal with in this course.

Each student in this course will have access to their own set of general simulators, such as a fractionation, flash drum, and heat exchanger simulator. Each piece of equipment will be started up by the trainees, and they will also have time to spend troubleshooting typical problems with the exchanger and separating units. The emphasis of the course is on optimizing tower operations while also promoting safety. Refineries, petrochemical sites, chemical factories, and any other establishments that use distillation columns can use the course material.

Target Audience

Process or controls engineers that are just starting out would benefit from an operations bootcamp

Course Objectives

• Adjust a cascade loop manually in a counter-current shell and tube heat exchanger. Analyze the effects of product yields and purities in distillation columns and flash drums. The impacts of adjusting throughput, operating temperature, operating pressure, and reflux ratio on product specifications are only a few of the crucial operational factors in a distillation column that should be noted.
• For exchangers, flash drums, and distillation columns, analyze trends and relate this data to various normal and abnormal scenarios.
• When running a distillation column, use the Think EQ.U.I.P.E.D. technique to increase your range of possible troubleshooting solutions.
• Exchangers and distillation columns are used to discuss and simulate HAZOP evaluations of typical troubleshooting scenarios with an emphasis on particular mitigation approaches.
• Consider important safety issues when starting up or restarting exchangers and distillation columns, and practice these startup procedures.
• Practice distillation column optimization methods such as dynamically modifying column operating settings to satisfy new requirements established by simulated changes in feedstock or market conditions.

Course Outlines

• A thorough startup method for a distillation column and heat exchanger
• Operating a hot side flow cascade loop with an outlet temperature and manually activating these controls
• In a shell and tube heat exchanger, simulating the effects of various flow variables (flow rate, temperature, and density)
• Simulating adjustments to a flash drum's flow rates, operating temperature, and operating pressure as well as the impact on product yields and purity that results from such modifications
• Utilizing a reboiler, an overhead condenser, a hot vapor bypass pressure system, and feed preheaters to operate a binary distillation column
• situations for troubleshooting a distillation column, such as preheat loss, reboiler fouling, air loss to controllers, tower flooding, and inaccurate instrumentation readings
• HAZOP analysis on cooling loss to a distillation column and simulating the necessary shutdown process
• A distillation column's feed composition is changed (additional lights are added to the feed), and the goal is to maintain product purity by altering critical operating factors.
• using the simulator's integrated dynamic profitability analysis to calculate profitability based on energy efficiency and minimal product requirements