ICTQual AB Level 6 International Diploma in Refinery Operations

Upon successful completion of the ICTQual AB Level 6 International Diploma in Refinery Operations, learners will be able to:

Year 1 – Foundation in Refinery Operations

Principles of Chemical Engineering

• Understand fundamental chemical engineering principles applied in refinery operations.
• Analyze chemical processes and reactions relevant to petroleum refining.
• Apply process calculations for mass and energy balances in refinery systems.
• Interpret chemical properties of raw materials and intermediate products.
• Demonstrate basic problem-solving in process optimization.

Introduction to Petroleum Refining

• Describe the history, structure, and purpose of modern petroleum refineries.
• Identify key refinery products and their industrial applications.
• Understand refining process flows and the role of different process units.
• Recognize operational challenges and safety considerations in refining.
• Explain the economic and environmental impact of refining operations.

Crude Oil Properties and Analysis

• Characterize crude oil types based on physical and chemical properties.
• Conduct basic crude oil analyses using standard laboratory techniques.
• Interpret analytical data to determine suitability for refining processes.
• Understand the effect of crude composition on refinery operations.
• Apply knowledge of crude properties to optimize process efficiency.

Refinery Process Units Overview

• Identify major refinery process units and their operational functions.
• Understand integration between distillation, conversion, and treatment units.
• Explain process flow diagrams and unit operations.
• Analyze interdependence of units for efficient production.
• Evaluate operational risks in refinery processes.

Distillation Principles and Applications

• Explain basic distillation concepts and separation mechanisms.
• Apply theoretical principles to crude oil fractionation.
• Interpret distillation column design and operation.
• Optimize distillation processes for maximum yield and efficiency.
• Assess the impact of operational parameters on product quality.

Heat and Mass Transfer in Refining

• Understand the fundamentals of heat and mass transfer in refinery systems.
• Apply heat exchanger and mass transfer principles to process design.
• Evaluate energy efficiency in thermal operations.
• Solve practical problems involving heat and mass balances.
• Analyze transfer phenomena to improve refinery performance.

Introduction to Catalysts and Chemical Reactions

• Describe the role of catalysts in refinery reactions.
• Understand basic reaction kinetics and thermodynamics.
• Identify catalyst types and their industrial applications.
• Analyze reaction pathways in hydroprocessing and conversion units.
• Apply knowledge to improve reaction efficiency and selectivity.

Process Instrumentation and Control Basics

• Understand common instruments used in refinery monitoring and control.
• Interpret sensor data and process signals accurately.
• Apply basic process control strategies to maintain stable operations.
• Recognize the importance of automation in modern refineries.
• Demonstrate safe handling and calibration of control instruments.

Health, Safety, and Environmental Awareness

• Identify potential hazards in refinery operations.
• Implement safety protocols and emergency response procedures.
• Understand environmental regulations and compliance standards.
• Promote a culture of safety and sustainability in industrial settings.
• Analyze risk factors to minimize accidents and operational incidents.

Industrial Laboratory Techniques

• Apply laboratory methods for analyzing refinery samples.
• Conduct experiments safely following standard operating procedures.
• Interpret lab results for process monitoring and optimization.
• Ensure quality assurance through proper laboratory techniques.
• Communicate findings effectively in professional reports.

Technical Report Writing

• Develop clear and concise technical reports for industrial contexts.
• Present data, analyses, and recommendations accurately.
• Apply professional formatting and documentation standards.
• Enhance communication skills for multidisciplinary teams.
• Interpret technical content for decision-making in refinery operations.

Introduction to Process Simulation Software

• Understand the role of simulation in refinery process design.
• Operate basic refinery simulation tools for process modeling.
• Analyze simulation results to optimize unit performance.
• Evaluate process scenarios using virtual modeling.
• Integrate simulation insights into operational decision-making.

Year 2 – Intermediate Refinery Operations

Advanced Distillation and Separation Techniques

• Apply advanced distillation methods to improve separation efficiency.
• Analyze complex separation processes using modern technologies.
• Optimize operational parameters for maximum product recovery.
• Evaluate the performance of distillation and extraction units.
• Solve industrial-scale separation challenges in refinery operations.

Hydrocracking and Hydrotreating Processes

• Understand the principles of hydrocracking and hydrotreating.
• Analyze reaction mechanisms and catalyst roles in these processes.
• Apply operational strategies to enhance product yield and quality.
• Evaluate process parameters for efficient hydroprocessing.
• Implement safety and environmental considerations in hydroprocessing units.

Fluid Catalytic Cracking (FCC) Operations

• Explain the FCC process and its role in converting heavy hydrocarbons.
• Monitor and optimize FCC unit operations for high efficiency.
• Analyze catalyst performance and reaction kinetics.
• Implement safety and environmental protocols in FCC units.
• Troubleshoot common operational challenges in FCC operations.

Process Control and Automation in Refineries

• Apply control strategies to maintain refinery process stability.
• Integrate automation systems to optimize operational efficiency.
• Monitor process parameters and respond to deviations effectively.
• Use control instrumentation to enhance safety and productivity.
• Analyze data from automated systems for decision-making.

Energy Management and Efficiency in Refining

• Assess energy consumption in refinery operations.
• Apply energy optimization techniques to reduce operational costs.
• Implement sustainable practices for efficient energy use.
• Evaluate the impact of energy-saving initiatives on production.
• Promote continuous improvement in energy management strategies.

Reactor Design and Optimisation

• Design chemical reactors for optimal refinery performance.
• Analyze reaction kinetics and thermodynamics in industrial settings.
• Apply optimization techniques to enhance reactor efficiency.
• Evaluate safety, environmental, and operational considerations in reactor design.
• Troubleshoot and improve reactor operations for consistent output.

Process Safety Management

• Identify and assess process safety hazards in refinery operations.
• Implement process safety management systems effectively.
• Conduct risk assessments and safety audits in industrial settings.
• Apply regulatory standards and best practices for hazard control.
• Promote a culture of safety and compliance across refinery units.

Refinery Production Planning

• Develop production plans aligned with operational goals.
• Coordinate resources, materials, and schedules for optimal output.
• Monitor production performance and adjust plans as needed.
• Analyze production data to improve refinery efficiency.
• Implement planning strategies that meet market and environmental requirements.

Quality Control and Assurance in Refining

• Apply quality control techniques to monitor refinery products.
• Conduct laboratory and process testing for product compliance.
• Implement quality assurance systems for consistent operations.
• Analyze data to detect deviations and improve product standards.
• Ensure compliance with international quality and safety standards.

Environmental Management and Sustainability

• Evaluate environmental impacts of refinery operations.
• Implement sustainable practices in production and waste management.
• Ensure compliance with environmental regulations and standards.
• Promote sustainable development strategies within refinery operations.
• Monitor and reduce emissions, waste, and resource consumption.

Petroleum Product Blending Techniques

• Understand the principles of blending petroleum products.
• Apply blending methods to achieve product specifications.
• Analyze the effects of blending on product performance.
• Optimize blending processes for efficiency and cost-effectiveness.
• Ensure safety and quality compliance in blending operations.

Data Analysis and Technical Communication

• Analyze refinery data for informed decision-making.
• Use statistical and technical tools to interpret operational results.
• Communicate technical information clearly in reports and presentations.
• Apply data insights to optimize refinery processes.
• Enhance collaboration through effective technical communication.

Year 3 – Advanced Refinery Operations

Advanced Process Optimisation and Troubleshooting

• Identify bottlenecks and inefficiencies in refinery operations.
• Apply optimization techniques to improve process performance.
• Troubleshoot complex operational issues using analytical methods.
• Implement solutions to enhance refinery productivity and safety.
• Evaluate continuous improvement strategies for advanced operations.

Refinery Project Management

• Plan, execute, and monitor refinery projects effectively.
• Apply project management principles to meet operational objectives.
• Manage resources, timelines, and budgets in refinery projects.
• Conduct risk assessments and implement mitigation strategies.
• Coordinate multidisciplinary teams for successful project delivery.

Catalysts and Reaction Kinetics in Depth

• Analyze catalyst behavior and reaction kinetics for advanced processes.
• Optimize reaction conditions for maximum efficiency and yield.
• Apply kinetic models to industrial refinery processes.
• Evaluate catalyst performance and lifecycle in operational units.
• Implement advanced strategies to enhance catalytic reactions.

Advanced Process Simulation and Modelling

• Utilize simulation software for process optimization and scenario analysis.
• Model complex refinery operations to predict performance outcomes.
• Analyze simulation data for decision-making and troubleshooting.
• Evaluate alternative process strategies using digital modeling.
• Integrate simulation insights into operational and strategic planning.

Corrosion and Maintenance in Refineries

• Identify causes and effects of corrosion in refinery equipment.
• Apply preventive maintenance strategies for operational reliability.
• Monitor equipment integrity and performance effectively.
• Implement maintenance schedules aligned with international standards.
• Ensure safe and efficient operation through corrosion control practices.

Energy Transition and Cleaner Refining Technologies

• Understand energy transition trends in the oil and gas sector.
• Apply cleaner refining technologies for sustainable operations.
• Evaluate alternative fuels, low-carbon solutions, and energy efficiency measures.
• Develop strategies to reduce environmental impact in refinery operations.
• Promote adoption of sustainable and innovative refining practices.

Risk Assessment and Hazard Analysis

• Conduct comprehensive risk assessments in refinery operations.
• Identify and mitigate potential hazards using industry-standard methods.
• Apply hazard analysis tools to enhance safety and compliance.
• Implement corrective actions for operational risk reduction.
• Promote a proactive safety culture in refinery environments.

Advanced Laboratory Techniques and Process Testing

• Conduct sophisticated analytical and process testing in refinery labs.
• Interpret test results to guide process optimization.
• Ensure compliance with international quality standards.
• Apply laboratory insights to troubleshoot industrial operations.
• Maintain rigorous safety and documentation practices in laboratory work.

Supply Chain and Logistics in Refining

• Understand the supply chain of crude oil and refined products.
• Plan and optimize logistics for efficient refinery operations.
• Analyze inventory management and distribution strategies.
• Implement best practices for cost-effective and timely delivery.
• Integrate supply chain management with production planning.

Capstone Project in Refinery Operations

• Apply comprehensive knowledge to a real-world refinery project.
• Demonstrate problem-solving, analytical, and technical skills.
• Conduct research, data analysis, and process optimization.
• Present findings and recommendations in professional formats.
• Showcase readiness for leadership and advanced operational roles.

Professional Development and Leadership in Energy

• Develop leadership skills for managing refinery teams and projects.
• Enhance communication, negotiation, and decision-making abilities.
• Apply professional ethics and industry standards in operational contexts.
• Promote continuous learning and career growth in energy sectors.
• Prepare for senior-level positions in refinery management.

Strategic Decision-Making in Refinery Management

• Analyze complex operational, financial, and environmental data.
• Make informed strategic decisions for refinery efficiency and profitability.
• Evaluate risk, market trends, and regulatory impacts on operations.
• Develop long-term operational strategies aligned with business objectives.
• Lead organizational change and innovation in refinery management.