Fluid Catalytic Cracking Technologies Training Course

Fluid Catalytic Cracking Technologies Training Course

Introduction

Fluid Catalytic Cracking (FCC) Technologies Training Course is designed to enhance technical expertise in petroleum refining, refinery process optimization, catalytic cracking, hydrocarbon conversion, and operational efficiency. Participants will explore advanced FCC process engineering, catalyst activity management, riser reactor hydrodynamics, coke formation, heat balance control, and refinery process simulation to improve unit performance, product quality, and operational reliability. The program also addresses the role of digital process monitoring, advanced process control (APC), predictive analytics, and data-driven decision-making in modern catalytic cracking operations.

Through industrial case studies, process simulation exercises, operational scenarios, and group discussions, delegates will develop practical skills for evaluating FCC performance, diagnosing process deviations, improving catalyst utilization, and implementing continuous improvement initiatives. The training also explores emerging developments in high-selectivity FCC catalysts, low-carbon refining, digital twins, artificial intelligence in refinery operations, and petrochemical integration. By the end of the program, participants will be better equipped to support safe, reliable, cost-effective, and competitive refinery operations in an evolving global energy and petrochemical industry.

Course Duration

5 days

Course Objectives

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

1. Explain the fundamental principles of fluid catalytic cracking technology and its role in modern petroleum refining.
2. Analyze FCC process flow schemes, reactor-regenerator configurations, and critical operating parameters.
3. Evaluate feedstock properties and their influence on conversion efficiency, product yield, and catalyst performance.
4. Apply catalyst science principles to improve activity, selectivity, stability, and catalyst life.
5. Optimize riser reactor operations to enhance hydrocarbon conversion and minimize undesirable reactions.
6. Monitor regenerator performance, catalyst circulation, coke combustion, and FCC heat balance.
7. Interpret process data to identify operating inefficiencies and improve FCC unit performance optimization.
8. Apply troubleshooting techniques to address catalyst deactivation, pressure-drop variations, and temperature instability.
9. Assess gasoline, LPG, propylene, light-cycle oil, and slurry-oil yields against refinery production objectives.
10. Utilize advanced process control, process simulation, and digital monitoring to support operational decisions.
11. Develop strategies for reducing energy consumption, catalyst losses, and greenhouse gas emissions.
12. Apply process safety principles to mitigate fire, explosion, hot-catalyst, and hydrocarbon-release risks.
13. Formulate continuous improvement strategies for refinery reliability, profitability, and sustainable FCC operations.

Target Audience

1. Refinery process engineers and chemical engineers.
2. FCC unit operators and panel operators.
3. Production supervisors and refinery operations managers.
4. Process control, instrumentation, and automation engineers.
5. Catalyst specialists and petroleum research scientists.
6. Refinery maintenance, inspection, and reliability engineers.
7. Process safety, environmental, and energy management professionals.
8. Refinery technical managers, performance analysts, and continuous improvement specialists.

Course Modules

Module 1: Fundamentals of Fluid Catalytic Cracking Technology

• Principles of catalytic cracking and hydrocarbon conversion.
• Role of FCC in integrated petroleum refinery operations.
• FCC process flow diagrams and major equipment systems.
• Characteristics of feedstocks, cracked products, and reaction pathways.
• Case Study: Evaluating the role of FCC in improving the conversion of heavy gas oil into high-value transportation fuels.

Module 2: FCC Feedstock Characterization and Preparation

• Physical and chemical properties of vacuum gas oil and other FCC feedstocks.
• Feedstock density, boiling range, sulfur content, nitrogen content, and metals.
• Effects of feed contaminants on catalyst activity and selectivity.
• Feed preheating, atomization, injection, and distribution techniques.
• Case Study: Assessing the impact of increased feedstock metals and Conradson carbon residue on conversion and catalyst deactivation.

Module 3: FCC Catalyst Science and Management

• Catalyst composition, zeolite structures, matrix materials, and additives.
• Catalyst activity, selectivity, attrition resistance, and hydrothermal stability.
• Catalyst deactivation through metals contamination, coke deposition, and steaming.
• Fresh catalyst addition, equilibrium catalyst management, and catalyst inventory control.
• Case Study: Comparing catalyst formulations to improve gasoline selectivity while maintaining LPG and light-olefin production targets.

Module 4: Riser Reactor Design and Operating Optimization

• Riser reactor configurations and hydrodynamic fundamentals.
• Catalyst-to-oil ratio, contact time, and reaction temperature management.
• Feed injection, vaporization, mixing, and catalyst distribution.
• Reaction kinetics, conversion severity, and secondary cracking reactions.
• Case Study: Investigating declining gasoline yield and optimizing riser temperature, catalyst-to-oil ratio, and contact time.

Module 5: Regenerator Operations and Heat Balance Management

• Regenerator design, coke combustion, and catalyst regeneration.
• Air distribution, oxygen availability, and carbon monoxide control.
• Regenerator temperature profiles and catalyst circulation rates.
• Heat balance between the reactor and regenerator systems.
• Case Study: Troubleshooting excessive regenerator temperature and elevated carbon monoxide levels while maintaining safe combustion conditions.

Module 6: FCC Product Yield Optimization and Quality Control

• Factors influencing gasoline, LPG, propylene, and light-cycle oil production.
• Gasoline octane, sulfur content, and product quality considerations.
• Dry gas formation, coke yield, and undesirable overcracking.
• Optimization of operating severity for refinery margin improvement.
• Case Study: Adjusting FCC operating conditions to increase propylene production while balancing gasoline yield, energy use, and product specifications.

Module 7: Advanced Process Control, Simulation, and Digital Technologies

• FCC process modeling and simulation for operational planning.
• Advanced process control (APC) and real-time optimization.
• Digital twins, predictive analytics, and artificial intelligence applications.
• Process data reconciliation, performance dashboards, and anomaly detection.
• Case Study: Using process data and simulation scenarios to identify the causes of unstable reactor temperatures and improve unit throughput.

Module 8: FCC Troubleshooting, Process Safety, and Sustainable Operations

• Diagnosis of catalyst circulation problems, pressure fluctuations, and equipment constraints.
• Management of catalyst losses, erosion, corrosion, and mechanical integrity.
• Process hazard analysis, emergency shutdowns, and safe operating procedures.
• Energy efficiency, emissions monitoring, and reduction of carbon intensity.
• Case Study: Developing a recovery plan for an FCC unit experiencing reduced throughput, increased catalyst losses, and elevated emissions while maintaining process safety.

Training Methodology

• Interactive lectures and presentations.
• Group discussions and brainstorming sessions.
• Hands-on exercises using real-world datasets.
• Role-playing and scenario-based simulations.
• Analysis of case studies to bridge theory and practice.
• Peer-to-peer learning and networking.
• Expert-led Q&A sessions.
• Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@datastatresearch.org or call +254724527104 

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

 We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to DATASTAT CONSULTANCY LTD account, as indicated in the invoice so as to enable us prepare better for you.