Fluid Catalytic Cracking
Consultant/Trainer: Stuart Foskett
Avoid Costly Bottlenecks
Catalyst deactivation, yield losses, and operational issues can quickly erode profitability. FCC units are the heart of many refineries, but inefficiencies lead to major setbacks.
This CPD Accredited hands-on course equips you with the knowledge to optimize FCC performance, troubleshoot challenges, and boost reliability. Learn from industry experts and gain practical strategies to enhance yields and minimize downtime.
Improve efficiency. Solve problems. Maximize output.
Cost
€3200
Location
Kuala Lumpur, Malaysia
Dates
H1 2026, dates to be confirmed
About the Trainer
Stuart Foskett is a Singapore-based process engineer with extensive expertise in fluid catalytic cracking unit operation, troubleshooting, and optimization. His deep understanding of FCC catalysts, additives, simulation models, and performance benchmarking gained through work with dozens of refiners worldwide ensures participants gain both technical and practical insights.
With his proven training capabilities through delivering numerous FCC courses, authoring technical papers, and serving on industry panels, Stuart delivers a comprehensive learning experience that bridges theory with real-world application for FCC professionals.
Participants
The ideal participants for this course are:
Process Engineers & Technologists – involved in FCC unit design, operation, optimization, or troubleshooting.
Operations & Shift Supervisors – responsible for FCC unit performance and operational decision-making.
Refinery Engineers & Managers – overseeing FCC operations, reliability, and economic performance.
Technical Service & R&D Professionals – working on catalyst selection, process improvements, or technological advancements.
New Engineers & Graduate Trainees – seeking a solid understanding of FCC fundamentals and best practices.
Learning Objectives
As a participant, at the end of the course you will be able to:
Understand FCC Fundamentals – Gain a solid grasp of FCC principles, including feedstock characteristics, reaction mechanisms, and process flow.
Optimize FCC Unit Operation – Learn how to improve yields, maximize product value, and enhance energy efficiency.
Troubleshoot Common FCC Challenges – Identify and resolve operational issues related to reactor-regenerator balance, catalyst performance, and equipment reliability.
Evaluate Catalyst Performance – Understand catalyst selection, deactivation, and regeneration to improve FCC efficiency.
Enhance Process Safety & Reliability – Learn best practices for maintaining stable operations, minimizing risks, and preventing unplanned shutdowns.
Apply Real-World Problem-Solving – Work through case studies and exercises to reinforce learning and improve decision-making in FCC unit operations.
DAY 1
- FCC Process Fundamentals
- Introduction and FCC overview
- Heat balance and Pressure balance
- FCC feed properties and reaction chemistry
- Fluidization and catalyst circulation
- Process Variable Effects
- Independent and dependent variables
- Effects of process variables, feed properties, catalyst properties
- Rules of thumb
DAY 2
- Fundamentals of FCC catalyst
- Activity control and metals management
- FCC catalyst formulation basics
- Catalyst additives
- Troubleshooting Common FCC Problems
- FCC Process Safety
- Inherent Process Risks in FCC
DAY 3
- Process Equipment Design and Operation
- Regenerator and Flue Gas System
- Riser / Reactor
- Product Recovery System
- Unit Monitoring and Optimization
- Test runs and data collection
- Use of process simulation models
- Strategies for process optimization
Programme
DAY 1
- FCC Process Fundamentals
- Introduction and FCC overview
- Heat balance and Pressure balance
- FCC feed properties and reaction chemistry
- Fluidization and catalyst circulation
- Process Variable Effects
- Independent and dependent variables
- Effects of process variables, feed properties, catalyst properties
- Rules of thumb
DAY 2
- Fundamentals of FCC catalyst
- Activity control and metals management
- FCC catalyst formulation basics
- Catalyst additives
- Troubleshooting Common FCC Problems
- FCC Process Safety
- Inherent Process Risks in FCC
DAY 3
- Process Equipment Design and Operation
- Regenerator and Flue Gas System
- Riser / Reactor
- Product Recovery System
- Unit Monitoring and Optimization
- Test runs and data collection
- Use of process simulation models
- Strategies for process optimization