A T3P - UGentPresentation of the different heat exchangers Heat exchanger sizing ... introduction to...

An international program with a large careeropening in a very promising sector

This international collaborative program is aimed at providing students withapplied training in petrochemicals, polymers and plastics, as well as withsubstantial background in chemical engineering and petroleum refining.

This program is open to young professionals or students who have justgraduated from an engineering school or from a university with an academiclevel recognized as being equivalent. They may apply to the program whetherthey have a general engineering background or have specialized in chemistry,chemical engineering, mechanics, polymers or material technology.

The program includes several visits to industrial sites and the coursesthemselves are given at three different locations: two terms at the IFP School,one term at McGill University in Montreal (Canada) and two weeks in Ferrara(Italy) within the framework of an agreement with La Sapienza University ofRoma.

The international character of this program also comes from the studentsthemselves who are from various countries all over the world.

In addition, most of the lecturers are highly experienced specialists fromindustry which gives students the opportunity to become familiar with variousaspects of professional life and may help them to develop a more open-minded approach.

Once they have graduated, the students may apply for a job in either R&D,process, engineering or operating activities, within a large industrial fieldranging from petroleum refining to plastic processing.

On top of its strong international character and the wide range of skills itbrings to students, the “must” of this program lies in the very promisingdevelopment of polymer applications.

Indeed, the diversity of grades and uses of polymers is already impressive, andthe potential for further improvements and new applications looks practicallyunlimited.

Jean-Bernard SigaudDirector, Center for Refining, Petrochemicals, Gas

Objectives and career openings

Program structure

Detailed course outline

Industrial partners and job opportunities

Faculty

On the web…

Contents

AT3P

Advanced Technology inPetrochemicals, Polymers and Plastics

[International Collaborative Program]

Language: EnglishDuration: from 16 to 22 months depending on the student's cursusDegree awarded: MSc degreeCursus: Conventional or “sandwich training”(alternating periods at school and in industry)

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http://www.mcgill.ca

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Petrochemicals, Polymers and Plastics (AT3P)

Objectives and career openings

Tailor-made to meet industry's requirements, the International Collaborative Program inAdvanced Technology in Petrochemicals, Polymers and Plastics is aimed at turningstudents into professionals skilled in monomer and polymer manufacturing, plasticsprocessing and applications of petrochemical products.

Participants will gain international experience by studying in Paris, Ferrara (Italy) andMontreal (Canada) as well as through contacts with other students, professionals andprofessors with highly diversified backgrounds.

On completion of this modular program, participants are able to:

■ take part in studies involving the design, sizing and technico-economic analysis of theprocesses and main equipment used in the petrochemical, polymers and plasticssectors;

■ become rapidly operational on taking up a position in production due to in-depthknowledge of the problems encountered in industrial plants, particularly where safetyand environment are concerned;

■ interface with research and development and production departments withincompanies;

■ handle the quality control aspects of manufactured products and liaise with suppliersand processors of plastic materials.

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Program structure

The content of the “Advanced Technology in Petrochemical, Polymers and Plastics”

program is divided in 14 courses (Co), including many case studies, projects and training

sessions.

Chemical Engineering applied to the refining andpetrochemical industry (in the IFP School - Paris)

■ Co 1 Thermodynamics/Refining Processes/Separation Processes■ Co 2 Thermal processes/Equipment■ Co 3 Design projects*

Petrochemicals and polymers manufacturing (in the IFP School - Paris except Co 6 in Italy)

■ Co 4 Basics for polymerization■ Co 5 Monomer and polymer manufacturing■ Co 6 From innovation to industrial reality■ Co 7 Technical and economic study■ Co 8 Finishing section design project

Training period (Co 9) (in industry)

Polymer properties and processing (in McGill University - Montreal)

■ Co 10 Polymer chemical engineering■ Co 11 Engineering properties of polymeric materials■ Co 12 Polymer processing■ Co 13 Polymer product and process design project■ Co 14 Polymer engineering laboratory

* This course is only available for trainees not following a “sandwich course”.

Co 1 : Thermodynamics/Refining Processes/Separation Processes ECTS Crédits: 10

■ Applied thermodynamics (fluid properties, liquid-vapor equilibria, models…)

■ Thermochemistry, kinetics and catalysis

■ Hydrocarbon physico-chemistry

■ Crude oils and petroleum products (analysis of crude oils, specifications of petroleum products, new trends)

■ Crude oil fractionation units (atmospheric distillation, vacuum distillation)

■ Refining processes (technical and economic description)

■ Distillation (operating parameters, process control)

OBJECTIVES

Master the main concepts of thermodynamics encountered in industrial processes dealing withfluids and know how and in which case they can be modelized.

Understand the practical meaning of a fluid’s physico-chemical behavior as well as of chemicalreactions.

Know how to use the specific correlations and main mixing laws for hydrocarbon properties.

Know the properties and main specifications for crude oils and petroleum products.

Master the fundamentals on refining processes (general process diagram, range of operations,economics).

Analyze the operating conditions for industrial columns, be able to detect problems in process runs,optimize the process control.

TEACHING FACILITIES

The teaching is backed up by a specific course manual including a large number of applications andcase studies based on industrial experience. A refinery visit is organized to see the different unitsand transpose the general refining diagram to the field.

The operational behavior of industrial distillation columns as well as the different optimizationstrategies are studied on dynamic simulators.

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Co 2: Thermal processes/Equipment ECTS Credits: 9

■ Laws in heat transfer (conduction, convection, radiation)

■ Operations of furnaces and boilers

■ Presentation of the different heat exchangers

■ Heat exchanger sizing

■ Study of materials (standards, corrosion, anticorrosion)

■ Laws in fluid dynamics (flow, circuit characteristics, pressure drops calculations)

■ Description of the main rotating machineries encountered in refinery and petrochemicalindustries (pumps, compressors, motors, turbines)

■ Instrumentation and Process control (sensors and transmission systems, controllers,control loops)

OBJECTIVES

Have an overall quantitative understanding of the phenomena encountered in heat transfer.

Understand the technology and operating conditions of thermal equipment.

Acquire knowledge of the main fluid properties and equipment materials.

Understand the operating conditions of rotating machinery.

Improve the understanding of control instruments and problems related to their use.

TEACHING FACILITIES

The teaching is backed up by a specific course manual including a large number of applications andcase studies based on industrial experience. A training session is organized in Normandy (with theESSO refinery) for students to see equipment operating on a plant (pumps, compressors, turbines,flares, pipes, safety valves, storage tanks, exchangers…) as well as to dismantle equipment and seeits different parts .

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Co 3: Design projects ECTS Credits: 11

■ Distillation sizing project: introduction to the PRO II simulation software, conception, designand cost estimation of a given industrial distillation column

■ Heat exchanger sizing project: selection criteria for different types of shells, principles ofheat exchanger sizing

OBJECTIVES

Know how to design industrial separation equipment involving distillation.

Be able to simulate columns by using shortcut methods as well as specific software used in industry.

Know thermal and mechanical design methods for shell and tube heat exchangers, reboilers andcondensers.

TEACHING FACILITIES

A project is given to the students (groups of two) in order for them to apply the design calculationmethods of distillation columns (by hand and using Pro II).

A second project enables students (groups of two) to understand interaction between mechanicalaspects and process requirements in the thermal and hydraulic design of heat exchangers.Calculations are carried out by hand and compared to the results given by the ST5 software fromHTRI (Heat Transfer Research Incorporation).

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Co 4: Basics for polymerization ECTS Credits: 8

■ Position of macromolecular chemistry (production, economics)

■ Polymer structure - conformation / properties relationships

■ Characterization methods relevant to industrial polymerization: molecular weightdistribution, melt index, intrinsic viscosity, Nuclear Magnetic Resonance, Gel PermeationChromatography, light scattering

■ Polymers derived from the main monomers

■ Chemistry of polymerization (chemical reactions, mechanism, kinetics, catalysts, mainreaction steps)

■ Different types of industrial processes (batch or continuous polymerization)

■ Modeling and design of chemical reactions and industrial reactors

■ Material properties

OBJECTIVES

Have an overview of the main polymer characterization methods used in industry.

Be able to link the properties to the structure and conformation of the polymer.

Have an overview of the different polymerization syntheses and the resulting polymers.

Be able to describe the main characteristics of each polymerization system from a chemical and aprocess point of view.

Be aware of the main development routes (types of catalysts, reactor and kinetic modeling).

TEACHING FACILITIES

The teaching is backed up by a specific course manual including a large number of applications. Avisit of a polymer research center (Atofina in Serquigny or of ExxonMobil Chemical Polymers inBrussels (Belgium)) allows the students to see the main characterization apparatus in operation aswell as some processing machines.

A visit of a supermarket and of a do-it-yourself center is organized to show the relationship betweenthe intrinsic properties of the polymer and the final application in food packaging and constructionmarkets.

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Co 5: Monomer and polymer manufacturing ECTS Credits: 13

■ Introduction to industrial polymer processes (importance of plastics in today's world, mainpolymerization processes, main industrial problems, methodology for polymer processdevelopment)

■ For each process of monomer and polymer manufacturing: presentation of the basicchemistry, the main steps of the industrial process, the technical evolution, the markettrends, the economics

■ Chemical engineering of non-newtonian viscous media: introduction to rheology, fluiddynamics, elements of polymer mixing and reactor engineering

■ Particulate operations, extrusion, static mixers (rheology of powders, centrifugal operations,pneumatic conveying, elutriation, etc.)

OBJECTIVES

Have a general overview of the industrial processes for the manufacture of monomers and polymers.

Be able to describe the chemical and technological aspects, the main operating parameters as wellas to give some economic data about each process.

Be able to explain the relations between the operating parameters and the final characteristics of theproduct.

Be aware of the main development routes for commodity plastics and for specialty polymers as wellas of the different competitors involved.

Acquire a general overview of specific problems encountered with polymeric viscous media, powderor pellets.

Be able to choose and design appropriate material for polymer production plants.

TEACHING FACILITIES

The teaching is backed up by a specific course manual including a large number of applications andcase studies based on industrial experience. Videos, samples and specific material are provided asoften as possible.

A visit of a steam cracking plant (ExxonMobil Chemical France, Notre Dame de Gravenchon)illustrates this petrochemistry course.

A visit of Gas Phase Polyethylene, butyl rubber and resins plants (ExxonMobil Chemical France) anda visit of a polyamide fibers plant illustrate the polymer manufacturing part.

These visits allow the students to meet process engineers and see the different constraints linked tothe operation of each specific unit.

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Co 6: From innovation to industrial reality ECTS Credits: 9

■ Literature survey project: elaboration of a report covering a specific industrial field for achemical firm that is considering entering new business areas

■ Training session in Basell Italy: Study of a propylene process, from research anddevelopment to pilot plant and to industrial plant

■ General industrial problems: process control, safety and environment, quality, logistics,insurance.

OBJECTIVES

Be able to perform a literature survey (information search) and write a report covering a specificindustrial field for a chemical firm that is considering entering new business areas by acquisitions,mergers or joint-ventures.

Have an overview of specific polymers or of more global subjects dealing with polymers (such asenvironment, process performance analysis, patents, specific markets, competition betweendifferent polymers for a given application...) including information on the historical development, themarket, the different producers, the production technologies, the economics, the patent situation ofthis field.

Acquire a general overview of the development of a product (Polypropylene) and the associatedprocess, from the research center to the industrial plant.

TEACHING FACILITIES

A literature survey project is carried out in groups of 3 to 4 students, contacts should be taken by thestudents with specialists from industry in order to gather up-to-date data and general informationbased on industrial experience.

A period of two weeks in Basell Italy is organized with lectures in the morning and visits in theafternoon (research center, laboratories, pilot plants, industrial plants...) as well as some practicalapplications. The teaching is backed up by a specific course manual including case studies based onBasell industrial experience.

A visit of INERIS (INstitut de l’Environnement industriel et des RISques at Verneuil en Halatte) givesa good introduction and demonstration to ignition and explosion hazards of pulverized polymer.

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Co 7: Technical and economic study ECTS Credits: 5

■ Definition of general topics: economic evaluation criteria, equivalent cost, profitabilityanalysis, discount rate, capital costs

■ Competitor analysis and benchmarking: selection of key performance indicators, predictions,experience curves, competitiveness, business performance

■ Evaluation project: evaluation of processes for the manufacture of a group of petrochemicalproducts, optimization of the balances, evaluation of the profitability

OBJECTIVES

Know the basic elements for investment decisions, capital budgeting.

Be able to evaluate the different economic elements of an industrial project including competitoranalysis and benchmarking.

TEACHING FACILITIES

The students (in groups of 3) have to evaluate, during a project, the different economic parametersof a petrochemical plant.

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Co 8: Finishing section design project ECTS Credits: 5

■ Realization of a block diagram and a process flow diagram

■ List of issues to be considered at the design stage

■ Collection of economic data on packaging costs, operation costs, investment costs

■ Definition of products lots, sampling, and control of the product quality

■ Elaboration of a production wheel for the reactors linked to the extruder wheels

■ Proposition on the main sizing of each section and equipment

OBJECTIVES

Understand the methodology for polymer project development.

Be able to design the finishing sections of a polyolefin plant including the production wheel, storagein silos, additive mixing, pelletizing, quality control, labeling, recycling of off-spec products, storagein bags or bulk, bagging and/or debagging lines up to the shipment of products out of the plantgate.

Know an order of magnitude of the price of off-spec products and specific material.

TEACHING FACILITIES

This project is carried out in groups of 3 to 4 students, contacts should be taken by the students withspecialists from industry in order to gather up-to-date data and general information based onindustrial experience.

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Co 9: Training period in industry ECTS Credits: 14

■ 3-month internship in industry (in R&D, process, engineering or operating activities

OBJECTIVES

Apply the knowledge and know-how acquired during the first modules to actual problemsencountered in the petrochemical industry.

Carry out an entire study within a team from an industrial plant or a process department and applyrigorous working methods.

TEACHING FACILITIES

To carry out this study, each student is integrated during three months within a team from theindustrial company and is supervised by a specialist. The student has to write a technical report onhis study and to present it at the end of the period in front of his supervisor and relevant engineersconcerned by the subject and also in front of a board of the IFP School.

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Co 10: Polymer chemical engineering ECTS Credits: 6

■ Condensation polymerization: kinetics of catalyzed and uncatalyzed reactions, linear andnon-linear polymers, gelation

■ Addition polymerization: kinetics of vinyl polymerization, emulsion and suspensionpolymerization

■ Average molecular weights and molecular weight distributions

■ Glass transition temperature and glassy polymers, plasticization

■ Morphology, crystallinity and orientation

■ Equations of state, solution properties, adhesion, stability and degradation of polymers

■ Plastic processing operations: typical processing sequences , resin-process-microstructure-product interactions

■ Polymer blends

OBJECTIVES

Review the main polymerization reactions, intrinsic characteristics of polymers.

Have a good understanding of the links between structure and properties of polymers in order todevelop new or existing products.

Be able to discuss with resin customers the different resin properties linked to the nature of thepolymer and to the processing.

TEACHING FACILITIES

The teaching is backed up by a specific course manual including a large number of applications andcase studies. The main intrinsic properties of polymers studied in this course will be applied duringexperiments in the laboratory and used for the polymer product and process design project.

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Co 11: Engineering properties of polymeric materials ECTS Credits: 6

■ Classes of polymeric systems (thermoplastics, thermosets, elastomers, fiber composites,etc.) applications

■ Associated material properties and standard testing

■ Engineering properties in the melt state: rheology, non-newtonian behavior, viscoelasticityand constitutive equations

■ Solid state engineering properties: linear and non-linear viscoelasticity, failure criteria

■ Miscellaneous engineering properties: thermal properties and heat transfer, permeability andmass transfer, electrical properties, optical properties

■ Property modifications: additives and modifiers

OBJECTIVES

Acquire an overview of the different polymers and their respective engineering properties,associating them to the use of polymeric materials in products.

Be able to run and analyze engineering properties tests in order to discuss with resin manufacturersand with polymer processing companies and propose alternatives corresponding to the engineeringproperties requested.

TEACHING FACILITIES

Numerous videos and slides are shown to illustrate the course.

The main intrinsic properties of polymers studied in this course will be applied during experiments inthe laboratory and used for the polymer product and process design project.

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Co 12: Polymer processing ECTS Credits: 6

■ Calendering, casting and coating

■ Single screw extrusion: screw and die design, co-extrusion, twin screw extrusion

■ Post-extrusion operations: fiber spinning, wire coating, film blowing

■ Molding operations: compression, transfer, injection and blow molding

■ Processing of foams, laminates, composites and blends

■ Instrumentation and process control, statistical process and quality control

■ Commercial software packages and applications

■ Microstructural and product quality control

OBJECTIVES

Have a survey of engineering properties of polymers and processing operations from a descriptive,modeling and design point of view.

Be able to model and design different polymer processing techniques: extrusion, injection, blowing, etc. taking into account the transport phenomena, polymer melt rheology, mixing, melting,pumping, and final shaping.

Be aware of the main software packages available for processing design.

TEACHING FACILITIES

A visit to the National Research Council / Industrial Materials Institute is organized to illustrate thiscourse.

The main polymer processes studied in this course will be studied further during experiments in thelaboratory and the main design methods used for the polymer product and process design project.

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Co 13: Polymer product and process design project ECTS Credits: 6

■ General principles involved in the design and optimization of products, equipment andprocessing conditions associated with the manufacturing of plastics articles

■ Selection of materials, commercial resins, manufacturing process, equipment, tool designand optimization of processing conditions

■ Environmental, safety and process and quality control considerations

■ Economic analysis manufacturing costs and product competitiveness

OBJECTIVES

Have a practical understanding of resin-process/final product relations in order to be able to select aresin and design a processing tool adapted to the manufacturing of a given plastic article.

Acquire a general overview of the main problems linked to the design and operation of polymerprocessing equipment.

Acquire a methodology for the project development of plastic articles and get an order of magnitudeof prices for specific equipment.

TEACHING FACILITIES

This project is carried out in groups of 3 to 4 students dealing with 3 to 4 articles. Contacts shouldbe taken by the students with specialists from industry in order to gather up-to-date data andgeneral information based on industrial experience.

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Co 14: Polymer engineering laboratory ECTS Credits: 6

Selected experiments covering some of the following aspects :

■ Osmometry, cryoscopy, intrinsic viscosity

■ Optical and polarized light microscopy

■ Calorimetry for the study of crystallization and curve kinetics

■ Tensile and impact behavior, dynamic mechanical properties, impact behavior

■ Capillary and rotational rheometry, melt fracture, dynamic rheological properties

■ Extrusion, compression molding, injection molding, mixing

OBJECTIVES

Have a practical understanding of the main polymer characterization methods.

Be able to compare the different processing techniques and corresponding engineering properties ofthe products.

Meet specialists and get information about the various research areas in polymer processing that arenow interesting industrials.

TEACHING FACILITIES

Characterization method laboratories and polymer processing machines are available for students tocarry out their specific study.

Experiments are carried out by the students within the National Research Council / IndustrialMaterials Institute (2 days), taking advantage of their specific processing machines and simulationprograms.

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Industrial partners and job opportunities

Industrial partnerships

In the last three years , more than 60% of the students of this program had an industrial partnershipduring their studies (sandwich training or pre-emption) with oil, petrochemicals, polymers, plasticsor engineering companies.

Job opportunities

Many opportunities are offered to engineers graduated from the AT3P program by oil,petrochemicals, polymers, plastics and engineering companies all over the world.

The diagram below shows that about 40% of AT3P engineers work in polymers (Atofina, Basell, BP, ExxonMobil Chemical, ICI, Rhodia, Solvay, etc.), 20% in engineering (Air Liquide, Jacobs Serete,Prosernat, Saipem, Technip, etc.), 20% in petrochemicals (Atofina, BP, ExxonMobil Chemical,Shell, etc.), 15% in plastics (Faurecia, UBE Engineering Plastics, Valeo, etc.) and 5% in refining.

Polymers 40%

Petrochemicals 20%

Plastics 15%

Refining 5%

Engineering 20%

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Faculty

The lecturers involved in the “Advanced Technology in Petrochemicals, Polymers and Plastics”program are professors from the IFP School, professors from famous international universities,engineers or researchers from the IFP group, specialists in continuous professional development andprofessionals from oil, petrochemicals, polymers, plastics or engineering companies, with highproficiency in the field.

Thus, more than 80 lecturers take part in this program. Most of them work in industry which leads toa teaching very close to the reality of industrial life.

The main companies and universities taking part in the program are listed below:

■ Atofina■ Axens■ CNRS■ Eastman Chemical■ Enichem Elastomeres■ ENSIC■ ESPCI■ ExxonMobil■ Faurecia■ IFP■ IFP Training■ INERIS

■ Krup Werner■ Nylstar■ Rhodia■ Shell■ Solvay■ Technip■ Total■ Universita di Roma La Sapienza■ University of McGill■ University of Western Ontario■ Waeschle Coperion

A wealth of general information about the IFP School,conditions of admission, etc., is available on the site

www.ifp-school.com

■ You are wondering about professional careers after graduating from the School?

Look under the heading: “Jobs and Careers” you will find some testimonials from former students…

■ You wish to know the length and schedule of your study program?

Life at the School > Life in the Centers > the center of your choice >Schedule of study programs

■ You want to know more about sandwich training at the IFP School?

Prospective students > Young graduates > Admission procedure >Financial conditions

■ You are not a young graduate and you would like information on the tuition fees?

Prospective students > Professionals > Admission procedure >Tuition fees for professionals

■ You are looking for the application form?

Prospective students > Young graduates or Professionals > Admission procedure >Download application form

If you have not found answers to your questions, contact us at [email protected]

École du pétrole et des moteurs / IFP School232, avenue Napoléon Bonaparte

92852 Rueil-Malmaison cedex - France

Tel.: +33 (0)1 47 52 64 57 – Fax: +33 (0)1 47 52 67 65

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On the web…

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