Sulfuric acid plant training for managers, engineers, and operators

Feature Sulfuric acid plant training for managers, engineers, and operators

By: Andrés Mahecha-Botero, Ph.D., P.Eng. and C. Guy Cooper, P.Eng., NORAM Engineering and Constructors Ltd.

Operating, maintaining, and upgrading a sulfuric acid plant is a challenging task. It requires knowledge about many disciplines that is difficult to convey to newcomers to the industry. Moreover, experience from senior engineers and operators is difficult to transfer within the organization. NORAM offers a systematic training course that utilizes knowledge management techniques to train managers, engineers, and operators based on the core knowledge already found within the plant personnel and enhanced by state-of-the-art know how of sulfuric acid manufacturing. A site meeting is held prior to preparing the course material so that the training seminar is customized to the plant’s specific flow sheet and equipment.

Benefits of NORAM acid plant training

A big part of the core insight about the key disciplines associated with sulfuric acid manufacture in a particular plant is often buried in plant manuals, operating procedures, and standards. It is often challenging for people in the industry to learn about sulfuric acid by reading manuals and documents. For this reason, a significant part of the learning occurs through many years of operating experience and discussions with senior personnel. NORAM’s acid plant training can improve and speedup this process. And as a side benefit, the training discussions can foster in-company discussion on specific areas of interest.

Understanding fundamentals

It is important to understand a number of fundamental concepts associated with process engineering, mechanical engineering, materials engineering, and instrumentation and control. These important concepts are key to understanding unit operations, equipment, and procedures. For this reason, unlike other training programs, a significant part of the course is dedicated to presenting the principles required to appreciate adequate operating practices. Key segments of the training course include: • Explain the process chemistry. • Provide gas cleaning and acid plant operating theories. • Explain designs and the subsequent operating basis. • Explain how the overall plant works.

A training course slide focused on the main process steps in a sulfuric acid plant.

Retaining knowledge of retiring personnel

It is important to ensure that an individual’s knowledge developed over decades of work does not leave the company when the person retires. The training program is designed to capture existing know-how and to transfer it to a wide range of people.

Training new personnel

Newcomers to the acid plant may not appreciate the complexity of the plant’s operation and the severity of the consequences of a possible error in operation. The training program allows newcomers to learn important aspects of sulfuric acid to become productive faster. Key segments of the training course include: • Explain what happens if there are process deviations. • Explain importance of taking measurements. • Describe consequences of not running a unit operation correctly.

A training slide about the importance of stick tests to prevent plant problems.

Typical slide about the importance of pressure surveys to prevent plant problems.

Training project people

Project managers and engineers often make important decisions that can affect plant performance. The training program ensures that people dedicated to projects benefit from the experience of others to ensure the best outcome for future plant projects. Key segments of the training course include: • Explaining different equipment available in the market. • Discussing equipment replacement strategies.

Standardizing know-how

operation. In some cases, this can be problematic since the plant may be operated differently from shift to shift. Moreover, some erroneous opinions can lead to problems in the plant. The acid plant training is useful to standardize the know-how across the facility.

The course also gives the opportunity to brainstorm about the possible causes and solutions to specific plant issues.

Equipment types and considerations are also discussed.

Training can help make sure all plant personnel have the correct information to solve a problem.

Acid plant training groups

NORAM’s specialists focus on developing the training material for a specific plant by taking inputs from senior plant people. Open discussions are essential to ensure the best possible learning outcome.

Typical training lasts about 20 hours, and classroom size can be customized to fit a particular scheduling need by the client. NORAM’s instructors specialize in acid plant design, project execution, and university teaching. A typical NORAM class consists of 20 to 30 people from all backgrounds and seniority levels.

NORAM Engineering and Constructors Limited supplies engineering studies, training, and improved equipment at attractive prices for sulfuric acid plants. For more information, please contact sulfuric@ noram-eng.com or (604) 681-2030. q