About the Distillation-Column Operation, Control & Troubleshooting Course

Time Training Center's 5-day/30-hour "Distillation Column Operation, Control & Troubleshooting" course is designed to equip participants with in-depth knowledge of distillation column design, operation, control, and troubleshooting.​ It covers the essential engineering principles behind tray and packed column systems, the thermodynamics of separation, and operational considerations for various conditions.

This comprehensive training emphasises root cause analysis of common malfunctions, including flooding, foaming, fouling, and tray damage. Participants will gain operational competence in running and controlling distillation units efficiently, improving product quality and yield through better column tuning and troubleshooting, and optimising energy consumption.

Through practical workshops and case studies, you will reinforce techniques for maximising column efficiency, energy utilisation, and high-purity product recovery while ensuring safe and stable operations. Our course integrates conceptual learning with interactive workshops, case-based learning, and technology integration to provide a holistic understanding and immediate applicability of skills.

Distillation-Column Operation, Control & Troubleshooting Course Objectives

​By the end of this Distillation-Column Operation, Control & Troubleshooting training course, participants will be able to:​

• Understand the principles and types of distillation processes and column configurations
• Gain operational competence in running and controlling distillation units efficiently
• Improve product quality and yield through better column tuning and troubleshooting
• Optimise energy consumption and separation efficiency in tray and packed columns
• Evaluate existing performance based on column internals and mechanical limitations
• Analyse operating difficulties such as tray damage, distributor malfunctions, and foaming
• Apply proven design principles for better control and maintenance planning
• Develop methods to improve throughput and minimise process instability

Training Methodology

We employ a comprehensive and applied learning strategy, integrating theory with real-world implementation:

• 30% Conceptual Learning: Expert-led sessions on catalytic theory and engineering principles
• 20% Interactive Workshops: Group exercises, presentations, and technical discussion forums
• 30% Case-Based Learning: Industry-specific examples and troubleshooting scenarios
• 20% Technology Integration: Digital tools, simulations, and catalyst modeling applications

Note: Instructors may adjust the training approach to fit technical requirements or participant engagement levels.

Course Instructor:

Our courses are delivered by highly qualified instructors with extensive experience in both industry and academia. With decades of hands-on expertise across a wide range of technical disciplines, our instructors are dedicated to providing high-quality, impactful training that equips participants with practical knowledge and skills they can immediately apply. Full instructor profiles are available upon request.

Course Fees

The course fee includes the following:

• Course Materials: Comprehensive participant materials, including lecture notes, slides, and case study documents. (Tablet or IPAD)
• Coffee/Tea: Provided on arrival and during morning and afternoon breaks to keep participants refreshed.
• Buffet Lunch: Served daily to ensure participants have an opportunity to network and recharge during lunch breaks.

Who Should Attend Our Distillation-Column Operation, Control & Troubleshooting Course?

This training course is highly beneficial for professionals involved in the design, operation, optimisation, and troubleshooting of distillation systems. It is especially relevant for those working in the oil & gas, petrochemical, and chemical processing industries.

• Lead Operators and Control Room Boardmen
• Process Engineers and Chemical Engineers
• Maintenance and Reliability Engineers
• Plant Supervisors and Shift Superintendents
• Commissioning Engineers and Start-up Teams
• Instrumentation and Process Control Technicians
• Technical Personnel involved in refinery and petrochemical operations

Course Outline

Module 1: Overview of Distillation Systems and Process Fundamentals

• Pre-Test assessment of existing knowledge
• Introduction to Distillation and Its Role in Process Engineering
• Types of Distillation Columns: Stripper, Evaporator, Vacuum, and Azeotrope Columns
• Tray vs. Packed Columns: Design and Operational Differences
• Distillation Stages and Efficiency Calculation Methods
• Factors Affecting Distillation Efficiency: Reflux Rates, Flooding, and Foaming

Module 2: Thermodynamics and Equilibrium Considerations

• Vapour-Liquid Equilibrium in Pure Components and Complex Mixtures
• Understanding Boiling Point, Vapour Pressure, Dew Point, and Bubble Point Concepts
• Heat and Mass Transfer in Distillation Processes
• Impact of Temperature, Pressure, and Composition on Column Efficiency

Module 3: Distillation Equipment and Column Design

• Types of Trays and Packings: Technical Characteristics and Operational Limits
• Distillation Column Sizing and Design Considerations
• Fouling and Vacuum Service Columns
• Design Features for Effective Liquid Distributors and Column Supports

Module 4: Commissioning, Start-up, and Process Control Optimisation

• Pre-Commissioning, Commissioning, and Start-up Procedures for Distillation Columns
• Process Control Systems: Monitoring and Controlling Key Variables (Pressure, Flow, Level, Temperature)
• Control Strategies for Distillation Columns: Manual vs. Automatic Control
• Normal and Emergency Shut-Down Procedures and Guidelines

Module 5: Troubleshooting and Performance Optimisation

• Common Operational Problems in Distillation Columns
• Tools for Diagnosing and Troubleshooting: Mass Balance and Flow Rate Analysis
• Strategies for Dealing with Tray Damage, Downcomer Sealing Issues, and Packed Tower Malfunctions
• Optimising Column Performance: Reducing Instabilities and Enhancing Yield

Module 6: Capstone and Assessment

• Review of Core Topics and Key Learnings
• Final Group Discussion and Q&A
• Post-Test Evaluation
• Certificate Presentation

Real-world Scenarios:

Participants will engage in discussions and activities based on actual industrial challenges, including:

• Diagnosing inefficiencies in a refinery distillation column due to poor internal design and operating conditions.
• Maximising distillation column performance by adjusting operational parameters to achieve high-purity separation.
• Troubleshooting foaming and flooding issues in distillation columns.
• Evaluating a distillation column’s capacity to handle varying feedstock qualities and adjusting parameters to maintain efficiency.
• Analysing column shutdown and emergency procedures to understand failure causes and develop corrective actions.

Course Completion Certificate

Upon completing your course at Time Training Center, you will be awarded an official Course Completion Certificate, recognising your achievement and the skills you've gained. This certificate validates your expertise and reflects the high standards of training you've undergone.