PRE 100
Process Engineering Essentials
COURSE SCHEDULE
| Code | Date | Location | price (€)* |
|---|---|---|---|
| PRE 100 | 2-6 Nov 2026 | Online | 3300 |
| PRE 100 | 10-14 Aug 2026 | Aberdeen | 4400 |
* Prices are subject to VAT and local terms. Ph.D. students, groups (≥ 3 persons) and early bird registrants (8 weeks in advance) are entitled to a DISCOUNT!
COURSE OVERVIEW
This is a 5-day course designed to provide participants with a complete understanding of process engineering fundamentals and their practical application in industrial facilities. The course begins with mass and energy balances, including steady-state calculations, recycle streams, and data reconciliation. Afterward, we explore fluid flow principles, covering pump and compressor selection, pipe sizing, pressure drop calculations, and common flow problems such as cavitation and surge.
This is followed by heat transfer fundamentals, including shell-and-tube heat exchangers, air coolers, fired heaters, and fouling mechanisms. We then present separation processes, including distillation, absorption, stripping, and flash drums, along with troubleshooting techniques for column upsets.
The fourth day covers reactor engineering basics, including batch vs continuous reactors, temperature and pressure control, catalyst deactivation, and signs of poor performance. The final day concentrates on process control, safety, and economics, including control loops, hazard reviews (HAZOP/ LOPA/ MOC), and equipment cost estimation.
This course provides participants with a solid understanding of core process engineering principles, including mass and energy balances, fluid flow, heat transfer, thermodynamics, and separation processes. These fundamentals are presented in the context of industrial applications such as oil refining, petrochemicals, and chemical manufacturing.
Participants will learn about process equipment including pumps, compressors, heat exchangers, distillation columns, reactors, and fired heaters. The course also covers catalysts, process control, safety systems, and troubleshooting techniques for day-to-day operations.
Real-world case studies and practical exercises help participants diagnose common process upsets, optimize operating conditions, and communicate effectively with operations, maintenance, and management teams. The final day focuses on process economics, energy efficiency, and plant utilities including steam, cooling water, and compressed air.
COURSE OUTLINE
5 days
Day 1: C: Mass and Energy Balances
Introduction - Process Balances
o Units & Dimensions
o Process Variables - Flow rate, pressure, temperature, composition, density, viscosity
o Flow Diagrams
o Piping and Instrumentation Diagrams (P&IDs)
o Mass & Energy Balances & Data Reconciliation
o Process Utilities – Steam, Cooling Water
Worked Example - Mass balance around a distillation column using field data
Day 2: Hydraulics and Fluid Flow
Fluid Behaviour and Fluid Movers
o Fluid Properties - Density, viscosity, Newtonian fluids, vapor pressure
o Pressure and head & Bernoulli's theorem
o Flow of liquids, Reynolds number, two-phase flow and pressure drop in pipes
o Pumps - Centrifugal vs positive displacement
o Pump performance curve, best efficiency point, NPSH
o Compressors & Blowers - Centrifugal, reciprocating, screw compressors
Worked Example - Valve Sizing
Day 3: Heat Transfer
Heat Transfer Mechanisms
o Conduction, Convection, Radiation
o Heat Exchangers - Shell-and-tube, plate, air-cooled
o Heat transfer coefficients and calculation
o Fouling factors, types of fouling and cleaning methods
o Heat Exchanger Networks - Heat recovery, minimum approach temperature
o Fired Heaters - Radiant and convection sections, skin temperatures, efficiency & draft
Case Study - Pinch basics
Day 4: Separation Processes and Reactors
Introduction to Separation Processes
o Phase behavior and vapour/liquid equilibria
o Distillation Basics and Distillation Equipment
o Gas / Liquid separation
o Absorption (amine) & Stripping (sour water)
o Reactor Fundamentals
o Catalysts and Catalyst Deactivation
Case Study - Distillation Column Design - McCabe-Thiele method
Day 5: Process Control, Safety, and Economics
Process Control & plant modifications
o Basic Control Loops - PID control
o Process Safety
• Management of Change (MOC)
• HAZOP methodology
• LOPA
o Process Economics
o Estimating the cost of process equipment and plants
o Case Study - Troubleshooting Process operations
Course Review & Open Forum Questions
INSTRUCTOR
Petro Teach Instructor
The Instructor holds BSc and PhD degrees from the UK and has over 30 years of experience in refinery technology, operations, and management with major oil companies. He currently works as a Senior Consultant at PetroTeach, specializing in oil and gas, process technology, safety, and environmental management.He is a Chartered Chemist and a member of the Royal Society of Chemistry (UK), as well as a member of the American Institute of Chemical Engineers (USA). He previously served as an Approved Safety Inspector at Cyprus Petroleum Refinery Ltd. He holds honorary academic appointments at several European universities and is involved in research in vacuum distillation, gas recovery, and pyrolysis. He is a team member of the Energy Integration Lab at Huddersfield University and heads the Waste to Plastics effort at a major recycling facility in Cyprus. Since 1996, he has delivered more than 250 professional training courses.
DESIGNED FOR
After completing this course, participants will be able to:
o Apply mass and energy balances – Perform basic steady-state calculations for process units and identify inconsistencies in operating data.
o Understand fluid flow principles – Calculate pressure drop, select pump and pipe sizes, and recognize cavitation, surge, and two-phase flow issues.
o Analyse heat transfer equipment – Evaluate heat exchanger performance, identify fouling, and understand shell-and-tube and air-cooled exchanger operation.
o Operate separation processes – Explain distillation, absorption, stripping, and flash operations, and troubleshoot common problems such as flooding and weeping.
o Recognize reactor fundamentals – Distinguish between batch and continuous reactors, understand temperature control, and identify signs of catalyst deactivation.
o Participate in process optimization and safety – Use basic process control concepts, interpret P&IDs, and contribute to hazard reviews and energy efficiency improvements.
COURSE LEVEL
o Intermediate to Advance
LEARNING OBJECTIVES
After completing this course, participants will be able to:
o Explain the refining value chain—from crude oil receipt to finished products (gasoline, diesel, jet fuel, LPG)—including key terminology and unit abbreviations
o Identify major refining processes—distinguishing between separation (CDU/VDU), conversion (FCC, hydrocracking, coking, reforming), and treating (hydrodesulfurization, amine scrubbing)
o Recognize the impact of impurities—describing how sulfur, nitrogen, metals, naphthenic acids, and chlorides affect catalyst life, equipment corrosion, and product quality
o Understand refinery utilities—explaining hydrogen production via steam methane reforming, cooling water and boiler feedwater systems, and sour water treatment
o Apply refinery economics—calculating crack spreads (3:2:1), interpreting complex margin vs. netback pricing, determining breakeven utilization, and optimizing blending for improved profitability
o Communicate effectively across departments—using correct refining terminology when collaborating with operations, engineering, finance, procurement, and planning teams
REGISTER
Registration is now OPEN!
* Prices are subject to VAT and local terms. Ph.D. students, groups (≥ 3 persons) and early bird registrants (8 weeks in advance) are entitled to a DISCOUNT!
For more details and registration please send email to: register@petro-teach.com
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