Fluid Catalytic Cracking Operation

Optimization & Troubleshooting

RAF/FCCSS-E

Who should attend?

  • This course provides a comprehensive understanding of operating, monitoring and optimizing the catalytic section of the FCC process.
Audience :
  • Engineers and technical staff interested or involved in the design or the operation of an FCC unit.

Level : Proficiency

Course Content

  • OVERVIEW OF THE FCC PROCESS

      • 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

      • 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

      • 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

      • Catalytic cracking reactions and resulting products.
      • Catalyst structure and catalyst mode of action.
      • Catalyst additives: CO promoter, metals scavengers, sulfur trap.
  • OPERATION & OPTIMIZATION

      • 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

      • 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.

Learning Objectives

  • 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.

Ways & Means

  • Applications, case studies based on typical industrial situations.