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Fluid Catalytic Cracking in Refineries | 2nd – 6th June 2025

This 5-day course provides a comprehensive understanding of the Fluid Catalytic Cracking (FCC) process, one of the most critical units ... Show more
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Course Overview

This 5-day course provides a comprehensive understanding of the Fluid Catalytic Cracking (FCC) process, one of the most critical units in petroleum refineries. The course covers the fundamentals of FCC operations, including feed characterization, reactor and regenerator design, process control, reaction chemistry, and performance optimization. Practical insights into maximizing FCCU performance and ensuring reliable operations will be emphasized.

Course Objectives

By the end of this course, participants will be able to:

  1. Understand the FCC process and its integration within the refinery’s configuration.
  2. Apply process control principles to FCC operations, including advanced control techniques.
  3. Characterize and analyze feedstocks for their impact on FCC performance.
  4. Evaluate and balance reaction and heat processes within the FCC unit.
  5. Maximize FCC unit performance through advanced reaction and regeneration technologies.
  6. Identify and troubleshoot common FCC operational issues, such as catalyst loss and fouling.
  7. Understand product treatments, including LPG and ultra-low sulfur gasoline (ULSG), and their significance in refining operations.

Target Audience

  • Refinery engineers and operators responsible for managing FCC units.
  • Process engineers and technical staff working with cracking technology in petroleum refineries.
  • Refinery maintenance and operations managers seeking to optimize FCCU performance.
  • Engineers and technologists interested in advanced process control and troubleshooting of FCC operations.

 

Daily Agenda

Day One: FCC Process

  • Refining Processes: Overview of key refinery processes and the role of FCC in refining operations.
  • Refineries Configuration: Understanding how FCC fits within the broader refinery configuration.
  • Fluidization and FCCU: Key principles of fluidization and its application in the FCC unit.
  • The Reactor Regenerator: Functions of the reactor regenerator in the FCC process.
  • Partial Versus Complete Combustion: Differences between partial and complete combustion in the FCCU.
  • The FCC Gas Plant: Key operations and technology in the FCC gas plant.
  • Product Treating: Techniques for treating products from the FCC process, including LPG and ULSG.

Day Two: Process Control and Feed Characterization

  • FCCU Process Control: Basics of process control in the FCC unit.
  • Basic Process Control: Overview of fundamental process control strategies.
  • Advanced Process Control: Techniques for implementing advanced control in the FCCU.
  • Hydrocarbon Classification: Classifying different types of hydrocarbons and their impact on FCC performance.
  • Feedstock Properties: Key feedstock characteristics and their effects on cracking operations.
  • Feedstock Impurities: Identifying and managing impurities in feedstock, such as metals, that affect FCC performance.
  • Metals in Feedstock: Impact of metals on catalyst deactivation and overall FCC performance.

Day Three: Reactions Chemistry and FCC Performance

  • Thermal Cracking Reactions: Overview of thermal cracking mechanisms and their role in FCC.
  • Catalytic Reactions: Understanding catalytic reactions in the FCC process and their influence on product yield.
  • Material Balance: Performing material balance calculations for the FCC process.
  • Heat Balance: Managing heat flow within the FCCU to optimize performance.
  • Pressure Balance: Understanding and controlling pressure balance within the FCCU.
  • Case Study: Application of material, heat, and pressure balances in a real-world FCC case study.

Day Four: Cracking Technology and Maximize FCCU

  • Reaction Technologies: Overview of key reaction technologies used in FCC operations.
  • Stripping Technology: Techniques for improving stripping efficiency in FCC units.
  • Regeneration Technology: Strategies for effective catalyst regeneration and maximizing catalyst life.
  • Resid Catalytic Cracking: Process and technologies for cracking heavier feedstocks in FCCU.
  • Maximize FCCU Performance: Methods for improving performance, product yield, and overall FCCU efficiency.

Day Five: Troubleshooting

 

  • Effective Troubleshooting: Key strategies and tools for troubleshooting common FCCU problems.
  • Catalyst Losses: Understanding the causes and effects of catalyst losses in FCC operations.
  • Coking/Fouling: Identifying and mitigating coking and fouling issues in the FCC unit.
  • Hot Gas Expanders: Troubleshooting and optimizing hot gas expanders in FCC operations.
  • Increase in Afterburn: Managing and mitigating afterburn issues in FCC units.

Why Choose this Course?

This course offers valuable insights into the most advanced and efficient methods for operating Fluid Catalytic Cracking units. It equips participants with practical tools and techniques for improving process control, optimizing product yield, and troubleshooting common operational issues. Professionals working in refineries will gain a deep understanding of FCC operations, enabling them to enhance efficiency, ensure product quality, and maximize the economic value of their refining operations.

Learning Outcome

Upon successful completion of the course, participants will be able to:

  1. Understand the fundamentals and complexities of the FCC process in petroleum refineries.
  2. Apply effective process control strategies to improve FCCU performance.
  3. Characterize feedstocks and manage impurities for optimal FCC operation.
  4. Analyze and optimize the reaction and heat balance within the FCCU.
  5. Implement advanced cracking and regeneration technologies to enhance FCCU efficiency.
  6. Troubleshoot common issues such as catalyst losses, fouling, and afterburn in FCC units.
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