Laboratory Assistant (Chemical Plant)

ITI Laboratory Assistant (Chemical Plant) Syllabus (English)

Course Overview

• Trade Name: Laboratory Assistant (Chemical Plant)
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in conducting chemical and physical analyses, handling laboratory equipment, preparing solutions, and ensuring safety in chemical plant labs, preparing them for roles as laboratory assistants, chemical technicians, or quality control analysts in chemical industries, or for self-employment in lab services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Chemical Laboratories: Role of lab assistants, types of chemical plants (petrochemical, fertilizer), lab functions.
• Safety Practices: Handling chemicals, PPE (gloves, goggles), fire extinguishers, Material Safety Data Sheets (MSDS), first aid.
• Basic Chemistry: Atomic structure, periodic table, chemical bonds, acids, bases, salts; pH and indicators.
• Lab Equipment: Burettes, pipettes, balances, thermometers, glassware; types, uses, calibration.
• Solution Preparation: Molarity, normality, percentage solutions; calculations and methods.
• Physical Parameters: Density, viscosity, boiling point, melting point; measurement techniques.
• Engineering Drawing: Reading lab equipment diagrams, flowcharts, piping layouts.

Trade Practical

• Safety Drills: Using PPE, handling chemical spills, operating fire extinguishers, studying MSDS.
• Equipment Handling: Cleaning and calibrating burettes, pipettes, balances; checking glassware integrity.
• Solution Preparation: Preparing standard solutions (0.1N NaOH, 1M HCl), verifying concentrations.
• Physical Measurements: Measuring density with hydrometers, viscosity with viscometers.
• Basic Titration: Performing acid-base titrations (e.g., HCl vs NaOH), using indicators like phenolphthalein.
• Data Recording: Logging observations, maintaining lab notebooks with accuracy.
• Project Work: Preparing and standardizing a 0.1N solution with titration verification.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Qualitative Analysis: Identification of cations (Na⁺, Ca²⁺) and anions (Cl⁻, SO₄²⁻); systematic procedures.
• Quantitative Analysis: Volumetric analysis, gravimetric analysis; principles and applications.
• Chemical Reactions: Types (redox, precipitation), balancing equations, stoichiometry calculations.
• Lab Techniques: Filtration, distillation, crystallization; equipment and processes.
• Water Analysis: Hardness, pH, dissolved oxygen; industrial significance in chemical plants.
• Instrumentation Basics: Spectrophotometers, pH meters, conductivity meters; working principles.
• Workshop Calculation: Solution strength calculations, percentage purity, yield estimation.

Trade Practical

• Qualitative Tests: Identifying unknown salts using flame tests, precipitation reactions.
• Volumetric Analysis: Conducting redox titrations (e.g., KMnO₄ vs oxalic acid), calculating concentrations.
• Filtration and Distillation: Separating mixtures, purifying liquids using distillation setups.
• Water Testing: Measuring water hardness with EDTA, determining pH with pH meters.
• Instrument Operation: Using spectrophotometers for absorbance, calibrating conductivity meters.
• Reaction Studies: Performing precipitation reactions, verifying stoichiometric ratios.
• Project Work: Analyzing a water sample for hardness, pH, and conductivity with a detailed report.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Organic Chemistry: Hydrocarbons, functional groups (alcohols, acids), nomenclature, basic reactions.
• Advanced Instrumentation: Gas chromatography, flame photometers; principles and applications.
• Thermal Analysis: Calorimetry, heat of reaction, specific heat; measurement techniques.
• Electrochemistry: Conductivity, electrodes, electrochemical cells; industrial relevance.
• Quality Control: Sampling techniques, BIS standards, quality assurance in chemical labs.
• Environmental Chemistry: Effluent testing, COD, BOD; pollution control measures.
• Maintenance Practices: Cleaning lab equipment, troubleshooting instrument faults.

Trade Practical

• Organic Tests: Identifying functional groups (e.g., aldehydes, ketones) using chemical tests.
• Instrumental Analysis: Measuring sample concentrations with gas chromatography, flame photometers.
• Thermal Experiments: Determining heat of neutralization using calorimeters.
• Electrochemical Tests: Measuring cell EMF, conducting conductivity experiments.
• Effluent Analysis: Testing industrial wastewater for COD, BOD, interpreting results.
• Quality Checks: Sampling raw materials, verifying purity with titration methods.
• Project Work: Conducting a complete analysis of an organic compound (identification and purity).

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Industrial Processes: Distillation, extraction, polymerization; lab roles in chemical plants.
• Advanced Analytical Techniques: Turbidimetry, nephelometry, titrimetric methods; applications.
• Data Management: Lab Information Management Systems (LIMS), data reporting, statistical analysis.
• Troubleshooting: Diagnosing errors in titrations, instrument calibration issues, sample contamination.
• Entrepreneurship: Starting a lab testing service, costing, market trends in chemical analysis.
• Safety Regulations: Hazardous waste disposal, OSHA guidelines, chemical plant safety audits.
• Emerging Trends: Green chemistry, automation in labs, Industry 4.0 applications.

Trade Practical

• Industrial Simulations: Performing lab-scale distillation, monitoring reaction yields.
• Advanced Analysis: Conducting turbidimetric tests, verifying results with standards.
• Data Entry: Using LIMS software for logging analysis results, generating reports.
• Troubleshooting Tasks: Correcting titration errors, recalibrating faulty pH meters.
• Field Exposure: Hands-on training in chemical plant labs or testing facilities (4-6 weeks).
• Safety Audits: Inspecting lab setups for compliance, managing hazardous waste disposal.
• Project Work: Analyzing an industrial sample (e.g., fertilizer) for composition, purity, and compliance.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Molarity, normality, dilution ratios, reaction yield, error analysis.
  • Science: Chemical kinetics, thermodynamics, surface tension, viscosity principles.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Lab equipment layouts, process flow diagrams, piping and instrumentation diagrams (P&ID).
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Report writing, presenting lab findings, teamwork.
  • IT Literacy: Using LIMS, MS Excel for data analysis, online research for lab standards.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like titrations, instrumental analysis, water testing, report preparation.
• Evaluation Criteria: Analytical accuracy, equipment handling, safety adherence, report quality.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Lab assistant, chemical technician, quality control analyst in chemical, petrochemical, or pharmaceutical industries.
• Self-Employment: Lab testing services, consultancy for chemical analysis, environmental testing.
• Further Studies: Diploma in Chemical Engineering, certifications in analytical chemistry or lab management.