Fluid Catalytic Cracking (FCC)

Overview

The fluid catalytic cracking unit is the economic heart of many refineries, converting heavy gas oils and residues into gasoline, LPG and light olefins. It is also one of the most complex units to operate, with a hot circulating catalyst, a tightly balanced reactor and regenerator, and a large main fractionator and gas plant. This course explains how the FCC works and how to run it safely and profitably. Participants study cracking chemistry and catalysts, the reactor-regenerator heat balance, catalyst circulation and pressure balance, and the effect of feed quality and operating variables on yields. The programme also covers the main fractionator, wet gas compressor and gas concentration unit, flue gas systems and emissions, and the most common upsets. Practical troubleshooting and optimisation run throughout the week.

Objectives

• Explain catalytic cracking chemistry and FCC catalyst properties
• Describe the reactor, regenerator and catalyst circulation system
• Apply heat and pressure balance concepts to FCC operation
• Relate feed quality and operating variables to yields
• Describe main fractionator and gas concentration operation
• Diagnose common FCC upsets and operating problems
• Identify opportunities to improve FCC margins and reliability
• Apply safe operating practices for start-up, shutdown and emergencies

Who should attend

Training methodology

The unit is built up section by section using clear diagrams, photographs of internals and real operating data. Participants complete heat balance and catalyst circulation calculations, analyse yield shifts from changes in feed and riser temperature, and interpret pressure surveys around the converter. Troubleshooting exercises use historical upsets such as catalyst losses, afterburn and loss of circulation. Throughout the week participants compare practices at their own units. A final integrated case study and assessment conclude the course.

Programme outline

Dates and fees

Fees are in GBP. per delegate.

Certificate

Frequently asked questions