Fluid Catalytic Cracking Training

Introduction

This course is designed to provide FCC operating and engineering personnel with an understanding of the current and typical operation, control, design, and troubleshooting of FCC Units during startup, normal operation, shutdown and emergencies. Participants will have an opportunity to obtain a broad working knowledge of FCC process and mechanical systems, to stay abreast of constantly changing procedures and technology, and to interact with others currently working in this field. This course has been developed to meet the needs of unit operators as well as engineers associated with the FCC unit. This highly practical course will give you a thorough understanding of the importance of the FCC process in your refining operation. You’ll learn about the entire Fluid Catalytic Cracking process, including process equipment design and operation, unit operations, catalyst and additive technology, fluidized solids fundamentals, and basic unit troubleshooting. Sessions will address real-world FCC issues in an enjoyable seminar format that maximizes interaction between course participants and facilitators. 

Objectives

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

• Describe UOP FCC technology
• Reference descriptions of the process flow and equipment, process control and metallurgy
• Identify the process flow of the UOP FCC Process
• Compare and contrast the effect of feedstocks

Training Methodology

The course is delivered in a combination of lecture-style and computer-based training. In addition, a significant amount of time is set aside for small working group activity when addressing case study problems. Extensive use is made of case study material to underline the key aspects of the course and to give the delegates exposure to current best practice.

Who Should Attend?

This course is designed primarily for personnel relatively new to fluid catalytic cracking, but those with considerable experience also will find the sessions valuable.

Course Outline

Process Fundamentals

Introduction to the FCC process, description of commercial unit configurations, process basics, flow schemes, and the position and importance of FCC in the modern fuels refinery

FCC Heat Balance

Reactor/regenerator energy balance as the basis for FCC operations and optimization

Reaction Chemistry & Kinetics

Overview of primary catalytic & thermal cracking reaction mechanisms

Catalyst Handling

Typical procedures and loading equipment for continuous addition of catalyst and additives

FCC Catalyst Technology

Zeolite synthesis, matrix technology, catalyst manufacture, and the impact of catalyst on unit operation

Process Variables

A detailed description of the effects of primary dependent and independent operating variables

Feed & Product Treating

Objectives and benefits of FCC feed pretreatment on FCC performance, along with typical product treating requirements

Convertor Pressure Balance

The importance of the reactor/regenerator pressure balance as a diagnostic tool

Fluidization & Standpipe Operation

Fundamentals of fluidized solids as they apply to the FCC process, and diagnosis of catalyst standpipe instability and catalyst circulation problems

Resid Processing Options

The benefits of processing heavy residual feedstocks in the FCC, along with the impact on catalyst, unit operation and hardware considerations

Process Equipment

Detailed discussion of the equipment utilized in the reactor/regenerator, main fractionators, and vapor recovery sections, typical design criteria, equipment reliability, and normal operations.

FCC Additives Technology

Optimum use of additives in the circulating catalyst inventory, environmental considerations and yield selectivity shifts

Catalyst Evaluation Techniques

Determining the performance of fresh catalyst candidates and equilibrium catalysts, and applying test results to commercial operation

Diagnosing Catalyst Losses

Diagnosing and minimizing FCCU catalyst losses, which have environmental and economic impacts for the FCCU

Equilibrium Catalyst Analysis

Interpretation of the chemical and physical properties of FCC equilibrium catalyst and use of the Ecat analysis report as a diagnostic tool

Unit Optimization

Techniques for manipulation of various cracking severity variables to optimize yield patterns and profitability

FACILITATORS

Session leaders are all EcoMan Fluid Catalytic Cracking Technical Service Specialists with years of hands-on experience and a wealth of practical knowledge.

Heat and Pressure Balances

Process Variable Effects