Design and operation of pilot-scale educational chemical plant

Abstract

The chemical industry has significantly contributed to human development over the past decades, experiencing rapid growth. However, despite strengthened safety regulations and corporate safety management efforts, industrial accidents continue to occur. This study proposes an educational approach to enhance safety and productivity by practicing in environments similar to actual industrial sites. By designing and operating an educational petrochemical plant, trainees gain hands-on experience with real equipment and materials, developing their ability to handle various situations. Survey results show that internal instructor-led training is the most common method, and understanding basic equipment is considered the most important competency for new employees. The educational plant prioritizes safety by using non-toxic raw materials, such as C10-15 normal paraffin, to minimize environmental risks and reduce waste generation. The educational satisfaction survey revealed high satisfaction with both the program and facilities, indicating that the educational petrochemical plant is effectively designed and operated. Additionally, the study shares problems encountered during actual operations and their solutions. This research demonstrates that practical training in real-world settings can play a crucial role in improving safety and productivity.