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FCC Unit Troubleshooting & Catalyst Optimisation

Enhancing Conversion, Product Yields, Catalyst Performance and Operational Reliability

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Why Choose Us

The FCC Unit Troubleshooting & Catalyst Optimisation training course develops the knowledge and analytical techniques needed to diagnose operating problems, assess catalyst performance and optimise conditions. The Fluid Catalytic Cracking unit is among the most important and profitable conversion units within a modern refinery. Its performance directly influences gasoline production, light olefin yields, refinery energy balance and overall profitability. Operations involve complex interactions between feedstock properties, catalyst activity, reaction severity, regenerator performance, equipment condition and operating constraints.

Poor conversion, excessive coke production, catalyst losses and regenerator afterburn can substantially reduce unit performance. Wet gas compressor limitations and deterioration in product quality can have the same effect. Effective troubleshooting requires a systematic understanding of process variables and their effects throughout the reactor, regenerator, fractionator and gas concentration sections. The course focuses on improving conversion, selectivity, product yields, energy efficiency, equipment reliability and safe operation.

This FCC Unit Troubleshooting & Catalyst Optimisation training course will highlight:

  • Analysing interactions among feedstock properties, catalyst activity and reaction severity
  • Troubleshooting poor conversion, excessive coke production and catalyst losses
  • Diagnosing regenerator performance problems and afterburn
  • Assessing wet gas compressor limitations and product-quality deterioration
  • Tracing process-variable effects across the reactor, regenerator, fractionator and gas concentration sections
  • Optimising conversion, selectivity, product yields, energy efficiency, equipment reliability and safe operation
Why Choose FCC Unit Troubleshooting & Catalyst Optimisation
Course Goals

What are the Goals?

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

  • Describe FCC reaction chemistry and fundamental process principles
  • Assess how feedstock characteristics affect unit performance
  • Examine reactor, riser and regenerator operating conditions
  • Determine the reasons for lower conversion and poor selectivity
  • Evaluate catalyst activity, circulation and inventory control
  • Enhance the performance of fresh catalyst and equilibrium catalyst
  • Resolve regenerator afterburn and combustion issues
  • Determine operating constraints within the fractionator and gas plant
  • Minimise catalyst losses, erosion, fouling and equipment damage
  • Enhance FCC yields, energy efficiency and operational reliability

Who is this Training Course for?

Who Should Attend?

This FCC Unit Troubleshooting & Catalyst Optimisation training course is designed for:

  • FCC Unit Process Engineers
  • Refinery Process Engineers
  • FCC Unit Operations Engineers
  • FCC Unit Supervisors
  • Refinery Operations Managers
  • FCC Unit Technologists
  • Process Control Engineers
  • Refinery Optimisation Engineers
  • Catalyst Technical Specialists
  • Refinery Troubleshooting Specialists
Learning Approach

How will this Training Course be Presented?

The course integrates technical presentations, process-flow diagrams, analysis of operating data, assessment of catalyst performance, troubleshooting activities and refinery case studies. Participants will investigate typical FCC operational issues and formulate practical preventive and corrective measures.

The Course Content

FCC Process Fundamentals and Feedstock Evaluation

  • Role of the FCC unit within the refinery configuration
  • FCC reaction mechanisms and catalytic cracking chemistry
  • Overview of reactor, regenerator and fractionation systems
  • Riser cracking, reaction time, temperature and catalyst-to-oil ratio
  • Feedstock properties affecting conversion and selectivity
  • Effects of Conradson carbon, sulphur, nitrogen and metals
  • Feed preheating, atomisation and injection performance
  • FCC material balance, conversion and yield calculations 

Reactor and Riser Performance Optimisation

  • Feed and catalyst contacting within the riser
  • Influence of riser outlet temperature and reaction severity
  • Catalyst circulation and catalyst-to-oil ratio optimisation
  • Feed nozzle performance and atomisation problems
  • Reactor cyclone operation and catalyst separation
  • Causes of low conversion and poor product selectivity
  • Dry gas, LPG, gasoline, light cycle oil and slurry yield control
  • Troubleshooting riser, reactor and disengager performance 

Regenerator Operations and Troubleshooting

  • Coke combustion and regenerator heat balance
  • Full-combustion and partial-combustion operating modes
  • Air distribution, combustion efficiency and flue-gas analysis
  • Dense-bed temperature and dilute-phase temperature control
  • Causes, consequences and prevention of regenerator afterburn
  • Troubleshooting high carbon on regenerated catalyst
  • Cyclone efficiency, catalyst losses and particulate emissions
  • Regenerator constraints, erosion and refractory concerns 

FCC Catalyst Management and Optimisation

  • FCC catalyst composition, properties and performance functions
  • Zeolite activity, matrix properties and pore structure
  • Fresh catalyst, equilibrium catalyst and catalyst inventory
  • Catalyst deactivation by steam, metals and contaminants
  • Effects of nickel, vanadium, iron, sodium and calcium
  • Catalyst additives for octane, SOx reduction and combustion control
  • Equilibrium catalyst sampling, testing and data interpretation
  • Optimising catalyst addition and withdrawal strategies 

Product Recovery, Troubleshooting and Unit Optimisation

  • Main fractionator operation and heat-balance management
  • Troubleshooting flooding, foaming, entrainment and slurry problems
  • Wet gas compressor performance and operating limitations
  • Gas concentration and LPG recovery-system troubleshooting
  • Product-quality problems and corrective operating actions
  • Identifying unit bottlenecks and throughput limitations
  • Energy efficiency, emissions reduction and reliability improvement
  • Integrated FCC troubleshooting and optimisation case study
Recognition

Certificate

  • • Wallstreet Development Academy Certificate of Completion for delegates who attend and complete the training course.

Frequently Asked Questions

The course focuses on troubleshooting FCC units and optimising catalyst performance. Its stated learning areas include enhancing conversion, improving product yields and supporting operational reliability. A more detailed breakdown of technical topics cannot be verified from the available course information.
The course addresses troubleshooting as a route to improving FCC unit performance and reliability. It is intended to strengthen the ability to consider operational issues in relation to conversion, yields and catalyst behaviour. The available information does not identify individual fault scenarios, diagnostic methods or troubleshooting exercises.
Yes, enhancing conversion and product yields is an explicit focus of the course. The FCC Unit Troubleshooting & Catalyst Optimisation training course approaches these outcomes through better troubleshooting, catalyst performance and operational reliability. The page does not specify particular yield targets, product streams or calculation methods.
Operational reliability is included because the course treats dependable FCC operation as a core performance objective alongside conversion, yields and catalyst effectiveness. This gives the training a combined focus on performance enhancement and troubleshooting. Further details about reliability practices, maintenance topics or risk controls cannot be verified from the course page provided.
This training aims to help participants improve FCC conversion, product yields, catalyst performance and operational reliability. It connects troubleshooting and catalyst optimisation with practical unit performance outcomes. Specific performance targets or quantified benefits are not provided on the course page.
The training focuses on catalyst optimisation as a key part of improving FCC unit results. It links catalyst performance with conversion, product yields and dependable operations. Specific catalyst types, evaluation techniques or optimisation procedures cannot be confirmed from the available page content.
The learning can be applied when reviewing FCC unit problems, catalyst performance, conversion results and product yields. It is designed to support operational decisions that contribute to more reliable unit performance. Specific workplace tools, case studies or implementation frameworks are not listed in the available information.
If you would like further information about this training course, our team is available to provide professional guidance and support: Email: [email protected] In-house training: https://www.wallstreetda.com/in-house-training

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