FCC Unit Troubleshooting & Catalyst Optimisation
Optimising FCC Conversion, Catalyst Activity, and Performance
Course Schedules
Training Course Overview
FCC Unit Troubleshooting and Catalyst Optimisation Training Course delivers essential technical insights into one of the most vital conversion units in modern petroleum refining. The fluid catalytic cracking unit directly dictates high-value gasoline yields, light olefin output, refinery energy integration, and overall operational profitability. Navigating complex process dynamics—from feedstock variations and catalyst activity to reaction severity and mechanical constraints—requires a structured diagnostic approach across the reactor, regenerator, main fractionator, and gas concentration sections.
Catalyst Optimisation Training Course techniques enable process personnel to systematically resolve critical unit disruptions, including conversion drops, excessive coke generation, catalyst carryover, regenerator afterburn, and wet gas compressor constraints. By applying rigorous analytical practices, delegates learn to stabilise reactor-regenerator heat balances, maintain product selectivity, and safeguard mechanical integrity.
Refinery Process Optimisation principles covered in this course ensure engineers and operational teams effectively optimize equilibrium catalyst performance, eliminate hydraulic bottlenecks, and maximize yield slates while ensuring plant safety and long-term asset reliability.
Training Course Objectives
FCC Unit Troubleshooting and Catalyst Optimisation Training Course empowers technical teams to systematically diagnose operational disruptions, optimize catalyst management, and maximize conversion efficiency across the refinery conversion block. Delegates gain actionable diagnostic methodologies to resolve complex reactor, regenerator, and fractionation bottlenecks while upholding operational safety and environmental performance.
Upon completion of this Training course, participants will be able to:
- Explain FCC reaction chemistry, catalytic mechanisms, and core process fundamentals
- Evaluate the impact of feedstock quality, Conradson carbon, and contaminant metals on unit yields
- Analyse riser, reactor, and regenerator operating parameters to maintain target conversion
- Identify root causes of poor product selectivity, excessive gas generation, and yield degradation
- Assess equilibrium catalyst activity, particle circulation, physical properties, and inventory management
- Optimise fresh catalyst addition rates, additive formulations, and equilibrium catalyst properties
- Troubleshoot regenerator afterburn, air distribution issues, and flue-gas combustion imbalances
- Diagnose main fractionator flooding, slurry circuit fouling, and wet gas compressor limitations
- Mitigate catalyst losses, cyclone erosion, refractory wear, and high-temperature equipment damage
- Enhance total product yields, energy performance, unit throughput, and overall operational reliability
Designed for
FCC Unit Troubleshooting and Catalyst Optimisation Training Course provides specialized technical instruction tailored for engineering, operations, and technical service personnel responsible for refinery conversion units. The curriculum equips multidisciplinary teams with the analytical capabilities needed to streamline operations, enhance yield performance, and prevent costly unit shutdowns.
This Training course is ideal for:
- FCC unit operators, shift supervisors, and field operating personnel
- Refinery process engineers, operations engineers, and production specialists
- Process control, automation, and instrumentation engineers
- Catalyst technical service specialists and refining technology engineers
- Maintenance engineers, reliability specialists, and mechanical integrity team members
- Inspection, corrosion, and stationary equipment engineers
- Laboratory chemists, quality control specialists, and refinery planning professionals
Learning Methods
FCC Unit Troubleshooting and Catalyst Optimisation Training Course utilizes an interactive instructional structure combining technical presentations with detailed process flow diagrams, real-time operating data analysis, and empirical catalyst testing interpretation. Participants work through structured troubleshooting exercises and detailed refinery case studies to examine common process upsets, evaluate diagnostic indicators, and formulate effective corrective actions. Through practical group discussions and analytical problem-solving sessions, delegates gain immediate expertise in applying advanced diagnostics to enhance unit conversion, selectivity, equipment reliability, and operating margins.
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
The Certificate
- Anderson Certificate of Completion for delegates who attend and complete the training course
In Partnership With
Learn more about this course
The course is suitable for mechanical maintenance engineers, reliability engineers, maintenance technicians, field service engineers, plant operators, production supervisors, condition monitoring specialists, and technical personnel responsible for industrial hydraulic machinery and fluid power equipment.
Yes. Participants who successfully complete the FCC Unit Troubleshooting & Catalyst Optimisation training course will receive a Anderson Certificate of Completion, demonstrating their commitment to professional development and continuous learning. This certificate provides formal recognition of the knowledge and skills gained during the course and can support professional growth and career progression.
Yes. The FCC Unit Troubleshooting & Catalyst Optimisation training course can be customised and delivered exclusively for organisations seeking a tailored learning solution. Course content can be adapted to address specific business objectives, operational challenges, industry requirements, and organisational priorities. Customised training allows teams to focus on the topics most relevant to their roles while supporting wider organisational development goals.
Participants attending the FCC Unit Troubleshooting & Catalyst Optimisation training course gain access to valuable industry insights, practical techniques, and internationally recognised best practices. The course helps professionals improve performance, strengthen confidence, broaden their perspective, and develop skills that contribute to both personal and organisational success. It also provides an excellent opportunity to exchange ideas and experiences with professionals from diverse sectors and backgrounds.
No. The FCC Unit Troubleshooting & Catalyst Optimisation training course is open to professionals from a wide range of backgrounds and experience levels. The course content is structured to provide value to both those who are new to the subject and experienced practitioners seeking to deepen their expertise. While some prior knowledge may enhance understanding of certain concepts, it is not a requirement for participation
The FCC Unit Troubleshooting & Catalyst Optimisation training course combines practical knowledge, current industry practices, and expert guidance to create a highly relevant learning experience. Rather than focusing solely on theory, the course emphasises practical application, enabling participants to develop skills and approaches that can be implemented directly within their organisations. This balance of knowledge and practical relevance helps participants achieve meaningful and lasting professional impact.
The FCC Unit Troubleshooting & Catalyst Optimisation training course uses a variety of learning approaches to maximise participant engagement and knowledge retention. These may include expert-led presentations, practical exercises, case studies, group discussions, scenario-based activities, and collaborative learning opportunities. This approach encourages active participation and helps participants translate learning into practical workplace results.
Yes. Industrial hydraulic systems are widely used across manufacturing plants, process facilities, heavy machinery, marine operations, utilities, and other industrial environments. The principles covered are relevant to professionals responsible for operating, maintaining, inspecting, or troubleshooting hydraulic equipment across a broad range of applications.
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