Unleashing Gasoline Production: Fluidized Catalytic Cracking (FCC) Operations Training Course

Introduction

The Fluidized Catalytic Cracking (FCC) unit is often considered the heart of a modern oil refinery, playing a pivotal role in converting heavy, low-value crude oil fractions into highly valuable transportation fuels like gasoline and light olefins (propylene, butylenes). This complex process involves the continuous circulation of hot, powdered catalyst between a reactor and a regenerator, driving cracking reactions that are essential for meeting market demand for high-octane fuels. Optimal operation of the FCC unit is critical for refinery profitability, product quality, and overall operational flexibility.

This intensive training course is meticulously designed to equip participants with a comprehensive and practical understanding of Fluidized Catalytic Cracking (FCC) operations. From exploring the fundamental principles of catalytic cracking and reaction mechanisms to mastering the design, operation, and troubleshooting of the reactor, regenerator, and fractionation sections, you will gain the expertise to manage this vital conversion unit effectively. This empowers you to optimize product yields, enhance fuel quality, improve energy efficiency, and strategically contribute to the safe and economic operation of the refinery.

Target Audience

  • Process Engineers and Chemical Engineers in Refineries.
  • Operations Managers and Supervisors of FCC Units.
  • FCC Unit Operators and Technicians.
  • Production Planners and Refinery Schedulers.
  • Technical Service Engineers for FCC Catalyst/Technology Vendors.
  • Maintenance and Reliability Engineers working on FCC Units.
  • Project Engineers involved in FCC Revamps/Expansions.
  • R&D Scientists and Engineers in Catalysis.

Duration: 10 days

Course Objectives

Upon completion of this training course, participants will be able to:

  • Understand the fundamental principles and reaction mechanisms of Fluidized Catalytic Cracking (FCC).
  • Grasp the key components and overall process flow of an FCC unit.
  • Analyze the operational parameters of the FCC reactor and regenerator.
  • Comprehend the role of FCC catalysts and their impact on performance.
  • Evaluate common operational problems in FCC units and apply effective troubleshooting methodologies.
  • Develop practical skills in optimizing FCC unit performance for yield, quality, and energy efficiency.
  • Navigate the complexities of FCC safety and environmental considerations.
  • Formulate robust strategies for enhancing profitability and reliability through optimal FCC operations.

Course Content

  1. Introduction to Fluidized Catalytic Cracking (FCC)
  • History and evolution of FCC technology.
  • Role of FCC in the refinery configuration and its economic importance.
  • Feedstocks for FCC units: vacuum gas oil (VGO), atmospheric residue.
  • Products of FCC: gasoline, LPG, light cycle oil (LCO), heavy cycle oil (HCO), slurry oil.
  • Overview of the FCC process flow diagram.
  1. Principles of Catalytic Cracking
  • Basic cracking reactions: carbon-carbon bond breaking.
  • Role of catalysts: zeolite-based catalysts, activity, selectivity.
  • Reaction mechanisms: carbonium ion chemistry.
  • Impact of temperature, pressure, and residence time on cracking.
  • Catalyst deactivation mechanisms: coking, poisoning.
  1. FCC Reactor Section
  • Riser reactor: principles, design, and operation.
  • Catalyst-to-oil ratio and its impact.
  • Feed injection systems and atomization.
  • Catalyst disengagement and cyclone separators.
  • Stripping steam and its role.
  1. FCC Regenerator Section
  • Purpose of regeneration: burning off coke from spent catalyst.
  • Types of regenerators: partial combustion, full combustion.
  • Air distribution and fluidization in the regenerator.
  • Temperature control and heat balance in the regenerator.
  • Flue gas treatment and emissions control (CO boiler, electrostatic precipitators).
  1. FCC Catalyst Management
  • Properties of FCC catalysts: surface area, pore volume, activity.
  • Catalyst circulation rates and inventory.
  • Fresh catalyst addition and spent catalyst withdrawal.
  • Impact of catalyst properties on product yields and quality.
  • Catalyst testing and performance evaluation.
  1. FCC Fractionation Section
  • Purpose of the main fractionator: separating cracked products.
  • Design and operation of the fractionator column.
  • Side stream draw-offs: LCO, HCO.
  • Overhead system: wet gas compressor, absorber-stripper.
  • Product specifications and quality control for FCC products.
  1. Operational Control and Optimization of FCC
  • Key control variables: reactor temperature, regenerator temperature, catalyst circulation.
  • Impact of operating parameters on gasoline octane, LPG yield, and LCO quality.
  • Advanced Process Control (APC) applications in FCC.
  • Online analyzers and real-time optimization.
  • Maximizing profitability through optimal FCC operation.
  1. Troubleshooting Common FCC Problems
  • Diagnosing catalyst circulation issues (e.g., poor fluidization, slugging).
  • Identifying and resolving temperature excursions in reactor/regenerator.
  • Handling feed quality variations and their impact.
  • Troubleshooting product quality deviations.
  • Managing equipment fouling and erosion.
  1. FCC Safety and Environmental Considerations
  • Major hazards in FCC operations: fire, explosion, CO exposure, catalyst dust.
  • Process safety management (PSM) principles applied to FCC.
  • Emergency shutdown (ESD) systems and interlocks.
  • Environmental regulations for FCC emissions (SOx, NOx, particulates).
  • Flare management and waste disposal.
  1. Advanced FCC Concepts and Future Trends
  • Deep catalytic cracking (DCC) for propylene maximization.
  • Residue FCC (RFCC) for processing heavier feedstocks.
  • Integration of FCC with other refinery units.
  • Digital twin technology for FCC simulation and optimization.
  • AI and machine learning for predictive maintenance and process control.
  • Role of FCC in the energy transition and petrochemical integration.

CERTIFICATION

  • Upon successful completion of this training, participants will be issued with Macskills Training and Development Institute Certificate

TRAINING VENUE

  • Training will be held at Macskills Training Centre. We also tailor make the training upon request at different locations across the world.

AIRPORT PICK UP AND ACCOMMODATION

  • Airport pick up and accommodation is arranged upon request

TERMS OF PAYMENT

Payment should be made to Macskills Development Institute bank account before the start of the training and receipts sent to info@macskillsdevelopment.com

For More Details call: +254-114-087-180

 

 unleashing Gasoline Production: Fluidized Catalytic Cracking (fcc) Operations Training Course in Botswana
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