5 days RAF/FCCSS-E
- Engineers and technical staff interested or involved in the design or the operation of an FCC unit.
- This course provides a comprehensive understanding of operating, monitoring and optimizing the catalytic section of the FCC process.
- Upon completion of the course, the participants will be able to:
- understand the exact role and process of an FCC unit,
- analyze the importance and impact of operating parameters on product quality,
- know about main potential incidents, their origin, consequences on safety, health and the environment,
- apply the most common preventive measures.
- No prerequisites for this course.
Ways and means
- Applications, case studies based on typical industrial situations.
OVERVIEW OF THE FCC PROCESS 0.25 day
- Aim of the fluid catalytic cracking unit and its place in the refining scheme.
- Characteristics of the feeds, impact on the process; incentive for conversion of heavy cuts.
- Mass balance, characteristics of the products and related treatments.
PLANT TYPICAL BALANCES 0.75 day
- Interpretation of the operating parameters:
- Heat balance and catalyst flow rate.
- Cracking conditions: thermal and catalytic severity, impact on operation and products.
- Pressure balance, fluidization and catalyst circulation; ∆P of slide valve and safety.
- Energy balance: heat recovery in the flue gas line and in the bottom pump-around.
FCC OPERATING PARAMETERS IN REACTION SECTION 2 days
- The following parameters:
- Different modes of changing the catalyst circulation.
- Control of the cracking temperature.
- Effect of the feed temperature, flowrate and chemical composition.
- Impact of acceleration or stripping steam.
- Pressure monitoring.
- are investigated, as well as their effect on balances, Δcoke, regenerator temperature and yields.
CATALYST MONITORING 0.5 day
- Catalytic cracking reactions and resulting products.
- Catalyst structure and catalyst mode of action.
- Catalyst additives: CO promoter, metals scavengers, sulfur trap.
OPERATION & OPTIMIZATION 0.5 day
- Different operating situations are analyzed to illustrate: optimization of LCO production; maximization of heavy feed processing under constraint of air flow rate limitation.
- Modification of the process for maximization of C3 & C4 olefins production, or maximization of gasoline.
INCIDENTS & TROUBLESHOOTING 1 day
- Incidents of heat balance: coke build up, afterburning, lack of coke, etc.
- Incidents of pressure balance: low pressure drop, reverse flow, failure of the wet gas compressor.
- Incidents on the energy recovery circuits: loss of boiler level, loss of circulation in the bottom pumparound, etc.
- Main interlock configurations.