Development Training Course on
FCC Unit Troubleshooting & Catalyst Optimisation
Enhancing Conversion, Product Yields, Catalyst Performance and Operational Reliability
Course Schedule
Get your PDF guide and explore all course details.
Why Choose FCC Unit Troubleshooting & Catalyst Optimisation Training Course?
The Fluid Catalytic Cracking (FCC) unit is one of the most important and profitable conversion units in a modern refinery. Its performance directly affects gasoline production, light olefin yields, refinery energy balance and overall profitability. However, FCC operations involve complex interactions between feedstock properties, catalyst activity, reaction severity, regenerator performance, equipment condition and operating constraints.
Operational problems such as poor conversion, excessive coke production, catalyst losses, regenerator afterburn, wet gas compressor limitations and product-quality deterioration can significantly reduce unit performance. Effective troubleshooting requires a systematic understanding of process variables and their effects across the reactor, regenerator, fractionator and gas concentration sections.
This FCC Unit Troubleshooting & Catalyst Optimisation Training Course provides participants with the knowledge and analytical techniques required to troubleshoot FCC unit problems, evaluate catalyst performance and optimise operating conditions. It focuses on improving conversion, selectivity, product yields, energy efficiency, equipment reliability and safe operation.
What are the Goals?
By the end of this training course, participants will be able to:
- Explain FCC reaction chemistry and process fundamentals
- Evaluate the influence of feedstock properties on unit performance
- Analyse reactor, riser and regenerator operating conditions
- Identify the causes of reduced conversion and poor selectivity
- Assess catalyst activity, circulation and inventory management
- Optimise fresh catalyst and equilibrium catalyst performance
- Troubleshoot regenerator afterburn and combustion problems
- Diagnose fractionator and gas plant operating constraints
- Reduce catalyst losses, erosion, fouling and equipment damage
- Improve FCC yields, energy efficiency and operational reliability
The Course Content
- 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
- 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
- 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 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
- 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
Certificate
- AZTech Certificate of Completion for delegates who attend and complete the training course
How Saudi Aztech Can Enhance Your Professional Career
At Aztech Saudi, we believe that professional development is the foundation of long-term career success. This training course is expertly designed to equip individuals with practical skills, forward-thinking strategies, and the confidence to navigate today’s dynamic work environments. Each course is delivered by subject matter specialists with extensive industry experience, ensuring that every learning experience is relevant, impactful, and aligned with real-world challenges. Whether you're looking to strengthen your technical expertise, enhance leadership abilities, or stay ahead of industry trends, Aztech Saudi provides the tools you need to elevate your performance and deliver measurable value to your organization.
Our training is more than just knowledge transfer—it’s a catalyst for career transformation. By participating in our courses, professionals gain a competitive advantage in their fields, improve their decision-making capabilities, and position themselves for new opportunities and leadership roles. We take pride in supporting individuals across various sectors and career stages, helping them unlock their full potential through high-quality, globally benchmarked learning experiences. With Aztech Saudi as your development partner, you’re not only investing in education—you're investing in a stronger, more successful future.
In Partnership With
Do you want to learn more about this course?
Register now or contact our team to discuss schedules, delivery formats, and customised options.
Related Courses
Check out other training courses might interest you
Frequently Asked Questions
Common questions about our training courses
Saudi AZTech offers a wide range of internationally benchmarked training courses across various disciplines including leadership, finance, engineering, project management, HR, and more. All courses are designed to meet the professional development needs of individuals and organizations in Saudi Arabia.
Yes, Saudi AZTech collaborates with globally recognized professional bodies to offer accredited training courses. Participants receive certificates that reflect international standards and support their career growth and industry credibility.
You can easily register through our website (aztech.sa) by selecting your preferred course and completing the online registration form. Our support team is also available to assist you with registration, invoicing, and any additional information you may require.
Our training courses are conducted in major cities across the Kingdom, including Riyadh, Jeddah, Dammam, and Al Khobar. We partner with top-tier venues to provide an optimal learning environment that combines comfort, convenience, and professionalism.
Absolutely. We work closely with Saudi-based organizations to develop tailored in-house training solutions that address specific business needs, departmental goals, and workforce development strategies—delivered onsite or at a preferred location
