Course Objectives:

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

1. Fundamentals of Fluid Catalytic Cracking (FCC)

• Understand the role of FCC in petroleum refining and its economic significance.
• Explain the key chemical reactions involved in catalytic cracking.
• Identify the different types of feedstocks processed in FCC units.

2. FCC Unit Process Flow and Equipment Design

• Describe the overall process flow of an FCC unit.
• Explain the design and operation of key FCC components, including:
• Feed Preheat and Pre-Treatment Systems
• Riser Reactor and Catalyst Circulation
• Regenerator and Flue Gas Handling
• Main Fractionator and Product Separation
• Analyze the impact of process variables on product yield and quality.

3. Catalyst System and Optimization

• Select appropriate FCC catalysts based on feedstock composition and desired product distribution.
• Understand catalyst deactivation mechanisms, poisoning effects, and regeneration techniques.
• Evaluate catalyst performance metrics and their impact on FCC operations.

4. Design and Operation of Associated Units

• Light Ends Recovery Unit (LERU): Understand the separation of light hydrocarbons (C3, C4, etc.).
• FCC Gasoline Hydrotreater (GHT): Learn sulfur reduction techniques and octane enhancement.
• Alkylation Unit: Study the conversion of FCC olefins into high-octane blending components.
• Sulfur Recovery Unit (SRU): Understand emissions control and sulfur recovery from FCC off-gases.

5. Process Optimization and Performance Enhancement

• Identify key process parameters affecting FCC performance and product yields.
• Implement energy efficiency measures, heat integration, and process automation strategies.
• Analyze and troubleshoot common FCC operational issues, including coking, catalyst losses, and equipment fouling.

6. Environmental, Safety, and Regulatory Considerations

• Identify major environmental concerns related to FCC operation.
• Apply best practices for emissions control (SO₂, NOx, particulate matter).
• Implement safety protocols for handling high-temperature and high-pressure operations.
• Understand relevant industry regulations and compliance requirements.

7. Troubleshooting and Case Studies

• Study real-world FCC process failures and troubleshooting methodologies.
• Apply systematic problem-solving techniques for process upsets and catalyst-related issues.
• Develop maintenance and reliability strategies to ensure long-term FCC unit performance.

Target Audience:

This course is designed for professionals involved in refinery operations, process engineering, and plant design, including:

1. Engineers & Technical Personnel

2. Operations & Maintenance Teams

3. Health, Safety, and Environmental (HSE) Professionals

4. Management & Decision-Makers