Catalytic Cracking & Reforming: Advanced 5-Day Training Course

Course Overview

This specialized Catalytic Cracking and Reforming training program delivers comprehensive technical expertise for refinery professionals across the Kingdom of Saudi Arabia (KSA), Oman, GCC countries (UAE, Qatar, Kuwait, Bahrain), and Africa. The course covers fluid catalytic cracking (FCC), catalytic reforming, catalyst technologies, process optimization, and operational excellence strategies essential for maximizing gasoline production, octane enhancement, and refinery profitability.

With the Middle East and Africa’s refining capacity focused on meeting growing domestic fuel demand and producing high-octane gasoline for export markets, this training addresses critical competencies for professionals at Saudi Aramco refineries (Ras Tanura, SATORP, YASREF, Jazan), Sohar Refinery (Oman), ADNOC Refining, KNPC (Kuwait), BAPCO (Bahrain), Dangote Refinery, EGPC facilities, and other major downstream operations implementing advanced conversion technologies to upgrade heavy feedstocks and enhance product quality.

Target Audience

• Process Engineers in FCC and reforming units across Saudi Arabia, Oman, UAE, Africa

• Catalyst Engineers managing catalyst performance and selection

• Operations Personnel in catalytic conversion units

• Technical Supervisors overseiring FCC and reformer operations

• Refinery Planners optimizing unit feedstocks and product slates

• Mechanical Engineers supporting rotating equipment in cat cracking units

• Project Engineers designing new catalytic units or revamps

• Technical Managers improving unit reliability and profitability

• Process Optimization Specialists maximizing yields and product quality

Day 1: Fluid Catalytic Cracking (FCC) Fundamentals

Morning Session: FCC Process Overview & Chemistry

• FCC unit role in modern refineries: converting heavy gas oils to gasoline and light olefins

• Catalytic cracking chemistry: carbonium ion mechanism, beta-scission, hydrogen transfer

• Feedstock characteristics: vacuum gas oil (VGO), atmospheric residue, hydrocracker bottoms

• FCC products: gasoline, light cycle oil (LCO), heavy cycle oil (HCO), coke, light gases (C3/C4)

• Process configurations: UOP, Shell, KBR technologies in GCC refineries

• Reactor-regenerator systems: side-by-side, stacked designs

• Regional applications: SATORP FCC, YASREF operations, ADNOC Ruwais, Sohar Refinery

• Feed pretreatment: hydrotreating for metals and sulfur reduction

Afternoon Session: FCC Reactor-Regenerator Systems

• Riser reactor design: catalyst-oil mixing, cracking reactions, residence time (2-4 seconds)

• Feed injection systems and atomization technology

• Catalyst separation: reactor cyclones, stripping section design

• Spent catalyst circulation and standpipe systems

• Regenerator design: combustion modes (partial vs. complete CO combustion)

• Catalyst residence time in regenerator (several minutes for coke burnoff)

• Heat balance: maintaining reactor-regenerator temperature equilibrium (500-550°C reactor, 650-750°C regenerator)

• Air distribution and flue gas systems

• Third-stage separator (TSS) and CO boilers for energy recovery

• Process flow diagram walkthrough: SATORP and Jazan Refinery FCC units

Day 2: FCC Catalyst Technology & Operations

Morning Session: FCC Catalyst Science

• Catalyst composition: zeolite (Y-type), matrix (kaolin clay), binder, additives

• Zeolite structure and acidity: cracking activity and selectivity

• Catalyst properties: surface area, pore size distribution, attrition resistance

• Equilibrium catalyst (E-cat) vs. fresh catalyst characteristics

• Catalyst additives: ZSM-5 for propylene production, octane enhancement, bottoms cracking

• SOx reduction additives for environmental compliance in GCC refineries

• Metals poisoning: nickel, vanadium, iron effects and passivation strategies

• Catalyst selection criteria for Saudi Arabian and African crude-derived feedstocks

• Catalyst management: addition rates, inventory control, activity maintenance

Afternoon Session: FCC Unit Operations & Control

• Start-up procedures: catalyst loading, air-in, light-off, oil-in sequences

• Normal operations: feed rate, reactor temperature, catalyst circulation control

• Catalyst-to-oil ratio (CTO): impact on conversion and product yields

• Reactor temperature control and its effect on gasoline/LPG yield balance

• Regenerator temperature management: excess oxygen, flue gas composition

• Wet gas compressor operations and fractionation section control

• Main fractionator: gasoline, LCO, HCO separation and product quality control

• Gas concentration unit (GCU) for LPG recovery

• Troubleshooting: catalyst loss, after-burn, poor product quality, mechanical issues

• Operational case studies: Saudi Aramco refineries, Sohar FCC unit performance optimization

Day 3: Catalytic Reforming Process & Technology

Morning Session: Reforming Chemistry & Process Design

• Catalytic reforming purpose: converting low-octane naphtha to high-octane reformate and hydrogen production

• Reforming reactions: dehydrogenation, isomerization, cyclization, hydrocracking

• Feedstock requirements: naphtha cut (C6-C11 range), sulfur specifications (<0.5 ppm), nitrogen limits

• Product characteristics: reformate (RON 95-105), hydrogen (70-90% purity)

• Process configurations: semi-regenerative, cyclic, continuous catalyst regeneration (CCR)

• UOP CCR Platforming, Axens Octanizing technologies in GCC refineries

• Reactor series design: typically 3-4 reactors in sequence with interstage heating

• Operating conditions: 480-530°C, 5-35 bar, hydrogen recycle systems

• Severity control: temperature, pressure, LHSV, H2/HC ratio effects on octane and yield

Afternoon Session: Reforming Catalyst & Equipment

• Reforming catalysts: platinum on chlorinated alumina, bimetallic (Pt-Re, Pt-Sn) formulations

• Catalyst deactivation mechanisms: coking, sintering, chloride loss, poisoning

• Catalyst regeneration: coke burn-off, oxychlorination, reduction procedures

• CCR units: continuous regeneration benefits for high-severity operations

• Reactor internals: catalyst loading, distribution trays, temperature measurement

• Reformer furnaces: multiple burner configurations, fuel efficiency in hot climates

• Hydrogen separation: PSA units, membrane systems for high-purity hydrogen

• Product stabilization and benzene saturation for gasoline pool compliance

• Major installations: SATORP CCR, YASREF reforming, ADNOC refining complex, Sohar catalytic reformer

Day 4: Process Optimization & Performance Enhancement

Morning Session: FCC Optimization Strategies

• Yield structure optimization: maximizing gasoline vs. light olefins (LPG) production

• Feedstock quality impact: Conradson Carbon, metals content, nitrogen, aromatics

• Operating variables manipulation: reactor temperature, CTO ratio, conversion targets

• Reducing slurry production and increasing middle distillate yields

• FCC gasoline quality: octane number, sulfur content, olefin content for Euro 5/6 specs

• Post-treatment options: gasoline desulfurization, alkylation of C4 olefins

• Catalyst optimization programs: testing, monitoring equilibrium catalyst properties

• Economic evaluation: margin optimization in Saudi and GCC markets

• Case studies: Debottlenecking strategies at Ras Tanura, ADNOC Ruwais FCC optimization

Afternoon Session: Reformer Optimization & Hydrogen Management

• Octane-yield optimization: balancing reformate octane against liquid yield losses

• Severity adjustments for market-driven octane requirements (RON 91, 95 gasoline grades)

• Hydrogen balance: reformer hydrogen as supply for hydrotreaters, hydrocrackers

• Maximizing hydrogen production vs. reformate yield for integrated refineries

• Pressure optimization: lower pressure increases octane but accelerates catalyst deactivation

• Catalyst cycle length extension strategies for semi-regenerative units

• Aromatics production: benzene, toluene, xylene (BTX) extraction for petrochemical integration

• Co-processing strategies with isomerization and alkylation units

• Linear programming integration: optimizing gasoline pool blending across Saudi Aramco and SABIC facilities

• Hands-on workshop: Optimization calculations and economic analysis

Day 5: Reliability, Safety & Future Technologies

Morning Session: Equipment Reliability & Maintenance

• FCC rotating equipment: wet gas compressor, main air blower maintenance strategies

• Catalyst cooler and slide valve maintenance in regenerator systems

• Refractory management: inspection, repair, failure modes in reactor and regenerator

• Cyclone inspection and catalyst loss prevention

• Expansion joint maintenance: critical for high-temperature service

• Reformer furnace tube monitoring: metallurgy, creep, carburization

• Reactor dumping and loading procedures during turnarounds

• Compressor anti-surge systems and performance monitoring

• Predictive maintenance technologies: vibration analysis, thermography, online monitoring

• Turnaround planning: typical 4-5 year cycles for FCC/reforming units in Saudi refineries

Afternoon Session: Process Safety & Emerging Technologies

• HAZOP and hazard analysis for catalytic units: fire, explosion, toxic release scenarios

• Emergency shutdown systems (ESD) and safety interlocks

• Catalyst handling safety: dust control, pneumatic conveying, personnel protection

• Hydrogen systems safety: leak detection, flame detection, inerting procedures

• Environmental compliance: NOx, SOx, particulate emissions control

• Flue gas treatment: SCR, ESP, wet gas scrubbers in GCC refineries

• Carbon intensity reduction: energy efficiency, CO2 capture opportunities

• Emerging FCC technologies: residue FCC (RFCC), deep catalytic cracking (DCC) for light olefins

• Petro-FCC: integration with petrochemical production (propylene, ethylene)

• Advanced reforming: aromatic complexes, continuous catalyst regeneration enhancements

• Future trends: Bio-feed co-processing in FCC units, circular economy integration

• Crude-to-chemicals direct conversion bypassing traditional refining (COTC projects in Jubail)

• Digitalization: AI-based optimization, digital twins for predictive operations, advanced process control

• Saudi Vision 2030 alignment: downstream diversification and chemicals integration

Learning Outcomes

Upon completion, participants will be able to:

• Understand FCC and reforming chemistry and process fundamentals thoroughly

• Operate and optimize catalytic cracking and reforming units for maximum profitability

• Manage catalyst performance: selection, monitoring, regeneration, troubleshooting

• Implement yield optimization strategies for gasoline and hydrogen production

• Troubleshoot operational problems and implement corrective actions effectively

• Apply advanced process control for enhanced unit stability and performance

• Ensure equipment reliability through proper maintenance and inspection programs

• Meet environmental regulations and product specifications (Euro 5/6 standards)

• Evaluate emerging technologies for refinery modernization and petrochemical integration

• Integrate units within overall refinery optimization frameworks used by Saudi Aramco and ADNOC

Course Delivery & Certification

• Format: Technical lectures, process simulations, interactive case studies, calculation workshops, unit walkthrough videos

• Simulation tools: Hands-on training with Aspen HYSYS, KBC Petro-SIM for FCC/reforming modeling

• Materials: Comprehensive technical manual, catalyst vendor data, design correlations, troubleshooting guides

• Certification: Professional certificate recognized by major refiners across KSA, Oman, UAE, Qatar, Kuwait, Bahrain, and Africa

• Language: English (Arabic translation support available for GCC participants)

• CPD Credits: Eligible for continuing professional development recognition

• Plant visits: Optional arrangements to SATORP, YASREF, or Sohar Refinery facilities (subject to approval)

• Locations: Riyadh, Jubail, Yanbu (KSA), Muscat, Sohar (Oman), Abu Dhabi, Dubai, Doha, Kuwait City, Lagos, Cairo

Why This Course is Essential for the Region

The GCC refining industry is investing heavily in conversion capacity to process heavier crude slates and meet stringent fuel specifications. Saudi Arabia’s mega-refineries (SATORP 400,000 bpd, YASREF 400,000 bpd, Jazan 400,000 bpd) feature advanced FCC and reforming technologies. Dangote Refinery’s 650,000 bpd capacity includes state-of-the-art catalytic units. Oman’s Duqm Refinery processes heavy crude requiring maximum conversion.

This training provides practical operational knowledge incorporating Saudi Aramco excellence practices, UOP and Axens technologies deployed across the region, and addresses specific challenges of hot climate operations, heavy feedstock processing, and integration with petrochemical complexes under Saudi Vision 2030 and Oman Vision 2040 diversification strategies.

Master catalytic processes. Optimize conversion. Maximize refinery value.