Unlocking Value: Catalytic Cracking and Hydroprocessing Training Course

Introduction

In modern petroleum refining, the ability to transform heavy, low-value crude oil fractions into lighter, high-value transportation fuels and petrochemical feedstocks is critical for maximizing profitability. Catalytic cracking and hydroprocessing stand as the cornerstone technologies enabling this vital conversion. While catalytic cracking breaks down large molecules using catalysts and heat, hydroprocessing uses hydrogen to remove impurities and upgrade product quality, forming a synergistic relationship that dictates a refinery's output slate and environmental compliance.

This intensive training course is meticulously designed to equip participants with a comprehensive and practical understanding of catalytic cracking and hydroprocessing technologies. From exploring the fundamental principles of catalysis and reaction mechanisms to mastering various unit configurations, operational optimization, and troubleshooting techniques, you will gain the expertise to manage these complex conversion processes. This empowers you to enhance product yields, improve fuel quality, meet stringent environmental regulations, and strategically contribute to the overall profitability and sustainability of refinery operations.

Target Audience

  • Process Engineers and Chemical Engineers in Refineries.
  • Operations Managers and Supervisors of Cracking/Hydroprocessing Units.
  • R&D Scientists and Engineers in Catalysis.
  • Production Planners and Refinery Schedulers.
  • Technical Service Engineers for Catalyst/Technology Vendors.
  • Project Engineers involved in Refinery Expansions.
  • Quality Control and Assurance Personnel in Refineries.
  • Academics and Students in Chemical Engineering/Petroleum Refining.

Duration: 10 days

Course Objectives

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

  • Understand the fundamental principles of catalysis and its application in refining.
  • Grasp the mechanisms and key parameters of Fluid Catalytic Cracking (FCC).
  • Analyze different hydroprocessing technologies (hydrotreating, hydrocracking) and their purposes.
  • Comprehend the role of catalysts in cracking and hydroprocessing reactions.
  • Evaluate operational challenges and apply troubleshooting methodologies for these units.
  • Develop practical skills in optimizing unit performance for yield, quality, and energy efficiency.
  • Navigate the integration of cracking and hydroprocessing within a refinery complex.
  • Formulate robust strategies for enhancing profitability and environmental compliance through these processes.

Course Content

  1. Introduction to Conversion Processes
  • Role of conversion processes in the modern refinery.
  • Why convert heavy fractions to lighter products?
  • Overview of cracking vs. hydroprocessing.
  • Economic drivers for conversion technologies.
  • Feedstocks for catalytic cracking and hydroprocessing units.
  1. Fundamentals of Catalysis
  • Definition of a catalyst and its role in chemical reactions.
  • Types of catalysts: heterogeneous vs. homogeneous.
  • Catalyst properties: activity, selectivity, stability.
  • Catalyst deactivation mechanisms: coking, poisoning, sintering.
  • Regeneration and rejuvenation of catalysts.
  1. Fluid Catalytic Cracking (FCC) - Principles
  • Basic concept: converting heavy gas oils into gasoline, LPG, and light cycle oil.
  • Reaction mechanisms: carbonium ion chemistry.
  • Key process variables: temperature, catalyst-to-oil ratio, residence time.
  • Types of FCC reactors: riser, downer, reactor-regenerator configurations.
  • Catalyst circulation and solids handling.
  1. Fluid Catalytic Cracking (FCC) - Operation and Optimization
  • FCC unit components: reactor, regenerator, fractionator.
  • Operational parameters and their impact on yields and product quality.
  • Troubleshooting common FCC operational problems (e.g., catalyst circulation issues, yield shifts).
  • Regenerator control and flue gas treatment.
  • Maximizing gasoline and propylene yields.
  1. Introduction to Hydroprocessing
  • Principles of hydroprocessing: reactions with hydrogen.
  • Purpose: impurity removal (sulfur, nitrogen, metals) and saturation of unsaturates.
  • Types of hydroprocessing: hydrotreating, hydrocracking.
  • Importance of hydrogen management and supply.
  • Hydrogen production technologies (e.g., Steam Methane Reforming).
  1. Hydrotreating Technologies
  • Purpose of hydrotreating: removing sulfur, nitrogen, oxygen, and saturating olefins.
  • Types of hydrotreating units: Naphtha HDS, Diesel HDS, Kerosene HDS, VGO HDS.
  • Catalysts used in hydrotreating: CoMo, NiMo on alumina.
  • Reaction conditions: temperature, pressure, LHSV, hydrogen partial pressure.
  • Meeting stringent fuel specifications (e.g., ultra-low sulfur diesel).
  1. Hydrocracking Technologies
  • Purpose of hydrocracking: converting heavy gas oils and residues into lighter, high-quality products.
  • Dual-functional catalysts: cracking and hydrogenation activity.
  • Types of hydrocrackers: single-stage, two-stage.
  • Products of hydrocracking: jet fuel, diesel, naphtha.
  • Advantages: flexibility in product slate, high-quality products.
  1. Hydroprocessing Unit Operation and Optimization
  • Hydrotreater and hydrocracker unit configurations.
  • Operational parameters and their impact on conversion and product quality.
  • Troubleshooting common hydroprocessing issues (e.g., catalyst deactivation, reactor hot spots).
  • Managing hydrogen consumption and purity.
  • Energy efficiency in hydroprocessing.
  1. Catalytic Cracking & Hydroprocessing Integration
  • How FCC and hydroprocessing units interact within a refinery.
  • Feedstock preparation for optimal performance of both units.
  • Product upgrading strategies using integrated processes.
  • Material balance and optimization across the integrated complex.
  • Economic implications of integration.
  1. Future Trends and Advanced Concepts
  • Novel catalysts for improved selectivity and stability.
  • Advanced process control and optimization for cracking and hydroprocessing.
  • Digital twin technology for real-time unit optimization.
  • Processing of heavier and unconventional feedstocks.
  • Role of these technologies in meeting future fuel specifications and environmental regulations.

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

 

Unlocking Value: Catalytic Cracking And Hydroprocessing Training Course in Nepal
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